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Old 10-14-2007, 09:55   #1 (permalink)
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EGR sensor bad?

My 2002 Sable has been running like crap for three weeks, starting when the engine light came on. The car sort of lunges or surges periodically while driving, particularly at 25-45 mph. It is as if the engine loses power and then regains it very rapidly, sometimes over and over again but with no regular interval, and with no distinctive sound. My gas mileage has also been awful. My friend suggested that it could be the EGR sensor, and lo and behold when we plugged in his diagnostic tool that is what it read out. Here are the error codes.

p1400 differential pressure feedback egr circuit low input
p0402 exhaust gas recirculation flow excessive detected
p0401 exhaust gas recirculation flow insufficient detected

What does all this mean? Any help is greatly appreciated.

Thanks, Eric
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Old 10-14-2007, 12:50   #2 (permalink)
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Re: EGR sensor bad?

Read this

Ford EGR
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Old 10-17-2007, 11:21   #3 (permalink)
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Re: EGR sensor bad?

Well I had my mechanic take a look at it. I took him about an hour or so of driving to feel it, but when he did he saw what I was talking about. It's a nasty problem. Really jolts the hell out of you. He couldn't duplicate the codes on his machine and took it to a transition specialist who said it isn't the trans. He doesn't know what to do, and aside from replacing the EGR sensor at a cost of 50 bucks and some painful labor (the EGR is in a tough to reach spot on the Sable) I don't know what to do.
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Old 10-17-2007, 15:58   #4 (permalink)
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Exclamation Re: EGR sensor bad?

Quote:
Originally Posted by itsnotbadgas
Well I had my mechanic take a look at it. I took him about an hour or so of driving to feel it, but when he did he saw what I was talking about. It's a nasty problem. Really jolts the hell out of you. He couldn't duplicate the codes on his machine and took it to a transition specialist who said it isn't the trans. He doesn't know what to do, and aside from replacing the EGR sensor at a cost of 50 bucks and some painful labor (the EGR is in a tough to reach spot on the Sable) I don't know what to do.
Uh, no it's not... it's right next to the EGR valve on a 3.0L Vulcan and directly in back of the upper intake manifold on a 3.0L Duratec. You just disconnect the wiring, and pull the sensor off the tubes. You may have to twist it a little or the hoses a little to get it off. Half an hour at the most.
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Old 10-17-2007, 19:01   #5 (permalink)
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Re: EGR sensor bad?

So what do you guys suggest I replace since it looks like I'll be doing this myself?
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Old 10-18-2007, 04:51   #6 (permalink)
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cool Re: EGR sensor bad?

It is the most common failure for these codes. There was a TSB for it out I don't remember the year span. My 2001 Taurus SEL was part of it.
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Old 10-18-2007, 09:42   #7 (permalink)
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Re: EGR sensor bad?

It's usually the DPFEgr sensor that is bad. To actually test to see if the EGR valve is working disconnect the vacuum line and while the car is idling put a hose on the valve vacuum port and manually apply vacuum. It should cause the engine to stumble.
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Old 10-30-2007, 15:36   #8 (permalink)
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Re: EGR sensor bad?

Hey guys, I tested the DPFE and was getting around 5 volts from the light green wire, while I should have been getting about 1. I replaced the DPFE today with a new 80 dollar one from the local dealership (its a dealership only part apparently) and it seems to work like a charm.

Thanks to all for the help!
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Old 10-30-2007, 19:12   #9 (permalink)
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cool Re: EGR sensor bad?

Quote:
Originally Posted by itsnotbadgas
Hey guys, I tested the DPFE and was getting around 5 volts from the light green wire, while I should have been getting about 1. I replaced the DPFE today with a new 80 dollar one from the local dealership (its a dealership only part apparently) and it seems to work like a charm.

Thanks to all for the help!
AutoZone sels them under the Wells brand for probably half of what you paid at the dealer. A few years ago I paid $70 for one at AutoZone, I've heard their price has since gone down. They call it an EGR pressure sensor.
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Old 11-01-2007, 00:03   #10 (permalink)
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Re: EGR sensor bad?

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Originally Posted by tbird100636
AutoZone sels them under the Wells brand for probably half of what you paid at the dealer. A few years ago I paid $70 for one at AutoZone, I've heard their price has since gone down. They call it an EGR pressure sensor.
The local auto parts store told me it is a dealership only part.
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