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Old 11-13-2010, 20:57   #1 (permalink)
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1997 Expedition 4x4 5.4 dtc 442

This issues has been going on for a couple of years. Code 442 is small EVAP system leak. I replaced the gas cap and the canister vent solenoid. The solenoid failed the bench test and I thought I had her fixed. No codes for 6 months but it's back. I've looked at all the hoses and connections that are along the drivers side frame rail and all looks fine. I replaced the hose that comes off the intake manifold. It was fine internally but had small cracks on the outside. I'm hoping someone on here had this problem and solved it.

Thanks,
Andy
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Old 11-13-2010, 21:57   #2 (permalink)
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Re: 1997 Expedition 4x4 5.4 dtc 442

look closely at the area where the gas cap gasket seats. I've heard of some knicks in the surface where it seals. It doesn't take much to cause a problem.
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Old 11-14-2010, 15:30   #3 (permalink)
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Re: 1997 Expedition 4x4 5.4 dtc 442

well Bert, it sounded plausible and I was hopeful but a close inspection of both sealing surfaces showed no reason for a leak there. I have the shop manual on CD and I need to read the section on the EVAP system over to remind myself exactly how it works and sets the 442 DTC. Then I'll make a plan find the leak.

Thanks for your reply,
Andy
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Old 01-15-2011, 22:26   #4 (permalink)
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Re: 1997 Expedition 4x4 5.4 dtc 442

well I finally got around to fixing this. It was the fuel pump assembly to fuel tank o-ring was not properly seated in one spot. Some bonehead (me) that replaced the pump in March of '09 let about an inch of the o-ring slip into the tank and out of the small groove they molded into the tank. This time I used an inspection mirror to make sure I could see the o-ring was in place all the way around before I tightened the nut. I was able to fix this with the truck on jack stands and the tank still tight and installed. A vent hose was in the way and had to be removed is all. Just prior to looking for the leak my wife had filled the tank and I could see the top of the tank wet with gas. That made my job so much easier.
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Old 01-16-2011, 09:12   #5 (permalink)
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Re: 1997 Expedition 4x4 5.4 dtc 442

Thanks for the update. We all make mistakes. Glad you got it fixed.
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