I have a 99 F150 that has had the DPFE sensor replaced 4 or 5 times now due to the Emissions related code, horrible gas mileage and rough running of the engine indicating a problem. After replacement, mileage returns to normal, codes go away and it runs smoothly.
The sensors have been replaced between 9 months to 18 month intervals when this problem returns.
My question is: what could be causing this part to keep failing? Is there some other engine or exhaust problem leading to this short life?
Thanks for any ideas to check on.

 

What are you replacing the DPFE with????? What brand??? Motorcraft is the brand to use. Some have posted about using DPFE from places like Autozone and getting a code like six months later.

 

Probably aftermarket junk....I hope he got a lifetime warrantied part!

Of course, it would help if we were told what the actual fault code has been.

Steve

 

Yeah, what brand sensor are you using?

 

I'm getting the ses code for the DPFE after replacing it 6 months ago with a motor craft one in my van. Paid like $90 for it. I'm gonna check my hose's and clean the throttle body and the EGR I also replaced that awhile back just throwing parts at it.. It was plastic the one I took out was metal. Maybe there all junk even the ones from ford.

 

I've replaced with Napa, Wells', parts from O'Reilly and Autozone's Duralast brand. Yes, they do have extended warranties, so most replacements have been covered without charge. But my question is why do they continue to fail, including the OEM Motorcraft part I began with?
The code is 0401 and when it occurs, you can measure the voltages to the part and they are no longer correct for the given state of the engine. the part stops functioning.
The hose is in good shape, I've measured the pressure and it's within tolerances.

 

The "OEM part" you began with was also crap.

Ford redesigned the sensor to make them more resistant to the moisture in the EGR system.

The new-stype plastic ones from Ford have not show the poor reliability of the other ones or the original OEM sensor.

Steve

 

Junk.
Junk.
Junk.
Junk.

I'll never understand why people insist on using aftermarket parts, especially sensors and other engine performance related parts.

 

bob, this is just for discussion.
Replace with Ford part for this function.
The part is a pressure transducer. The program is so tight for the values it needs to see from the DPFE that aftermarket units often do not maintain the tight tolerence needed over the longer term. It is in the range of 1 percent to failure indication as percribed by the EPA regulation, for tolerence. That's tight for an auto system, over time.
The part has to endure contaminated exhaust gas with water and acid content, so it's hard on this part. This is why using a Ford replacement is advised.
Check to see if the connector might have a problem with corrosion or poor physical condition.
If you keep having a problem, it may be fuel and driving time contributuing to the issue and one of those things you might have to roll with.
Gas is loaded with alcohol everywhere now, so the motors don't get the mileage once made. Alcohol absorbs water as well.
Good luck.

 

Yep, you have tried the rest now try Motorcraft. I ordered a Motorcraft DPFE of ebay for under $50 bucks shipped to my door. Like to be ready for problems beforehand. DPFE is one of the parts where others wont do.