Intermittent P0402 (2022 Hybrid)

[BAScott62]

I was getting an EGR code this past summer, can't remember the actual number, but while looking around under the hood noticed the coolant level was low. Topped it off and the codes stopped. Could have been a coincidence but worth a quick look see.

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[HeyBales]

https://www.mavericktruckclub.com/forum/threads/p0402-required-egr-valve-cooler-replacement.74922/

 

[Vettereddie]

https://www.mavericktruckclub.com/forum/threads/p0402-required-egr-valve-cooler-replacement.74922/

I'm the OP of the linked thread, valve and cooler replacement (fortunately under warranty) did not fix the issue, dealer reached out to Ford corporate and parts were ordered for an install this Friday. Will find out what's getting replaced when I get the invoice.

 

[SuperTongue]

I'm the OP of the linked thread, valve and cooler replacement (fortunately under warranty) did not fix the issue, dealer reached out to Ford corporate and parts were ordered for an install this Friday. Will find out what's getting replaced when I get the invoice.

Lucky yours hit under the 36k mark, hoping mine is just a sensor or something. Will find out tomorrow on mine and update here when I get the invoice.

 

[SuperTongue]

Looks like it was the DPFE sensor that @jorl mentioned. Guess moisture accumulated in it and caused it to fail.

Will post an update with the actual invoice info once I get it (have to wait until tomorrow for them to get the part). Not covered under any warranty still on the truck, unfortunately.

 

[jorl]

Looks like it was the DPFE sensor that @jorl mentioned. Guess moisture accumulated in it and caused it to fail.

Will post an update with the actual invoice info once I get it (have to wait until tomorrow for them to get the part). Not covered under any warranty still on the truck, unfortunately.

I can't wait to hear this...

 

[SuperTongue]

I can't wait to hear this...

I can't remember the exact numbers he gave me on the phone, but it's definitely in the hundreds of dollars for the part and labor. I was getting a couple other things done and remember the total, just not exactly what it was.

Will drop the actual numbers tomorrow.

 

[SuperTongue]

For those interested, cost was $542.02 before tax

Here's the invoice as well. Hopefully the problem stays resolved. Looks like the part was RX6Z-5L200-A.

Summarizing for anyone searching around in the future:

Ford Pass alert text:

Service Engine Soon Warning

What Is Happening?
Your service engine soon alert is on because an issue was detected with the engine. For diesel engine vehicles, this can cause a loss of performance.

What Should I Do?
Check the engine air filter and the tubes that connect to the air filter housing to make sure they are not damaged and fully connected. The installation of non-factory exhaust parts can also cause this issue. If this alert returns the next time your vehicle is driven, contact your dealership as soon as possible for service.


Actual code pulled from scanner: P0402 - Exhaust Gas Recirculation (EGR) Flow Excessive Detected

Mileage: 40,000

Warranties:
Bumper to Bumper / 36,000 mile warranty expired.

Powertrain warranty would not cover it as it's an emissions part.

Federal emissions warranty is 24,000 miles / 2 years, obviously outside of that. The 8/80,000 mile emissions warranty only covers major parts of which this sensor and the EGR are not.

The hybrid components warranty itself (100,000 miles / 8 years) also does not cover it.

 

[BlueSpec1]

I remember having to replace DPFE sensor one of a 2001 Ranger.

Workshop manual shows 2.5L Maverick's is:

 

[SuperTongue]

I remember having to replace DPFE sensor one of a 2001 Ranger.

Workshop manual shows 2.5L Maverick's is:

Seems pretty straightforward, would think most people could DIY it at least based on that location.

 

[skinnyboy]

Ouch. $380 labor .

 

[jorl]

friggin flat rate is a joke...unless yer FORD

 

[icegradner]

Ouch. $380 labor .

At least $300 of which goes into the dealerships pocket. Most techs make like $35/h or less.

 

[skinnyboy]

At least $300 of which goes into the dealerships pocket. Most techs make like $35/h or less.

Yeah, it's a sad situation. The gleaming glass palaces they call dealerships around here must cost a fortune. Used to get parts at a small local hole in the wall dealership to "help them out". They finished construction on their new site a couple of years ago:

Surprisingly they had a sign looking for mechanics.

Cheers.

 

[Techcar]

The 2019 and up rangers have the same problem with the same sensor. Most of us buy them off of RockAuto or around $50 and replace them ourselves.

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