I'm back again, this time its my wifes Explorer. Engine light came on, took it to Autozone had the code read P1401 DPFE high voltage? I replaced the DPFE sensor and drove it for about 3 days and the CEL came back on. I'm stumped, any suggestions? Its a 2001 Ford Explorer 5.0L V8, AWD, 86K miles. Thanks in advance.

 

The 1401 code says the PCM sees a continious 'high' siganl (4.96 volts) from the DPFE (not high voltage).
Clear the code and see what you get again by scan because the code may be a different one.
Which DPFE do you have? three lead or four lead device.
If 4 lead, suspect the connector/ wire harness. There may be a cross giving the constant high.

 

Thanks Bluegrass, I'll go look right now.

 

Its a 3 pin connector, I can go get the code pulled, but I'm like 30 minutes away from the nearest AZ. Anymore suggestions?

 

After the engine light last came on I thought I would clean the throttle body, so I did and all was well for a few days. Yesterday, I was driving it and the SUV surged a little when driven at constant speeds, engine light once again came on, so I took it back to AZ. They pulled the code and it was P0401, not enough EGR flow. I took her home, sprayed the EGR thru the throttle body with carb cleaner and threw a can of BG 44K fuel system cleaner in it. I unhooked the battery to get the light off and just got back from driving it about 50 miles. It still surged just a little, but no engine light yet. I was going to take the EGR off, but the steel hose on the bottom of it is rusted on, and I can't get it off. Somebody help me, what should I do to stop the surging?

 

Based on how you are reporting your experiences, the 'few days' was IMO the 3 test periods the program uses before turning on the CEL for a 401 failure.
You initally reported a 1401 failure.
You need to drive 3 cycles to be sure what you now have is either a good or bad result then reinvestigate for any new code that returns.

 

I guess I'll keep on driving it and see what breaks next. I'm seriously considering trading it for a Toyota. I like the vehicle, but don't have time or extra money to deal with problems. Thanks for your help Bluegrass, I'll report back if anything else happens.

 

The problem is not of such a serious nature as to cause you to trade the truck for some other one unless you have excess capital to spend.
IMO, even letting a dealer do the fix is cheaper than trading.
The 'delayed' 401 code just involves the emissions testing of the EGR system.
The PCM routine calls for the EVR to be pulsed enough to allow about a 10% flow rate that is measured by the DPFE acrossed a restriction in the pipe from the exhaust manifold thru the EGR valve into the intake.
If the DPFE fails, it'self, the small hoses are in trouble or there is a restriction in the path other than the calibrated one, then a code is set.
This peticular test take 3 drive cycles to set a code from the first time it is detected or the code is cleared. This is why many get fooled into thinking they got the problem only to have it return a few full drive cycles later.
An immediate 401 code upon start-up is usually a hard fault with the EGR system operation before the 401 low flow test is ever attempted. So the 401 code has at least two implications.
Good luck.