I have replaced the DPFE and cleaned the hoses leading to and from as well as tested the EGR and EVP valves and they pass both tests but still the lite is set.
I was told that the next thing to do was remove and clean the EGR but I cannot budge it. It is very rusted at the exhust manifold and I am afraid if I try to wrench any more on it it will snap off inside the header.

The truck runs fine no problems other than that ******* lite that will not go away.

I have tried PT Blaster and lots of effort anyone with similar experiences please let me know what you have done?

I would not care that much except that MD emissions will fail the truck for lite for their OBD II test.

Thanks for your help!!

 

I wish I had a solution for you, but I do feel you pain. I did a rebuild on my motor and ended up junking the stock headers due to rust build up on the header studs and EGR tube. I actually just cut parts of the header up so I could get them out. I'm moving to Phoenix this week. From now on, I won't have to worry about rust again. (Not like it is here in CNY! )

 

Whoa...you don't need to clean the valve or the hoses...just undo the tube at the valve and unbolt the valve from the intake box.

THEN clean the ports in the intake box between the valve and the opening.

There are tons of posts, pictures an tips on here...just do a search for "EGR" or "P0401".

 

EGR pipe fitting from manifold is frozen stuck cannot move without risk of breaking tube. I have tried several times and soaked it with PT Blaster. If I remove the 2 bolts holding the EGR valve I am not sure I can move it enough without breaking the metal tube.

I rechecked my DPFE sensor this morning and it was only reading 1.59 volts on the back of the plug with the Key on. So I went to FORD and bought another sensor and put that on and reset the computer and drove about 40 miles today and no lite!! Maybe the last sensor NAPA only 1 month old was bad as well?

Hope this fixes the problem so I can return the EGR tube and the manifold fitting they ran about $70.

Thanks again any more input will be appreciated.

 

It's no sweat at all moving the tube. It's pretty nice stainless that's just not going to break.

The chances of two sensors quitting on you are about zero. Just unbolt the plenum and clean it...it's not as big of a deal as you think it is. Heck, you don't even have to move the valve -- just unbolt it and take the plenum box off and leave the valve where it is.