CHECK ENGINE CODE: P0402 FIX (EGR FLOW EXCESSIVE) — UPDATED SENSOR + EASY DIY (HYBRID)

[Joaquin F]

Wanted to share this in case it helps someone else out. I’ve been dealing with a P0402 (EGR Flow Excessive) on my 2022 Maverick Hybrid, and I think I finally tracked it down.

Part numbers (important)

I went down the rabbit hole on this and found that Ford has updated this sensor a few times:

JX7A-5L200-AD (original / older)
JX7Z-5L200-A (updated)
RX6Z-5L200-A (current replacement)

If you’re ordering, just go straight to this one:
https://www.oemfordpartsdirect.com/oem-parts/ford-sensor-assembly-rx6z5l200a

Location
It’s on top of the engine and super easy to get to. I attached a photo of the sensor and where it sits on the motor so you can double check before ordering.

Dealer vs DIY
Dealer quoted me $260.29.
But after going back and forth with them, they were actually really cool about it and said:
“If you are somewhat mechanically inclined, yes, you should be able.”
“The part # that we are recommending is RX6Z5L200A”

So it seems like most of the cost is labor.

Quick shoutout
I appreciated that they didn’t just push the repair, helped confirm the correct part, and were honest that it’s something I could do myself.

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[Joaquin F]

This is for the Ford Maverick Hybrid; Hopefully someone can break it down similar to this for ecoboost! ONCE AGAIN; My findings is about HYBRID

 

[rclee]

Thank you @Joaquin F I have been having that P0402 CEL off and on for about 3 months. The truck ran fine and there was no hit in MPGs. The site you linked worked perfectly and the price was amazing. I almost bought a couple of them I cant wait to get rid of that CEL!

 

[Joaquin F]

Thank you @Joaquin F I have been having that P0402 CEL off and on for about 3 months. The truck ran fine and there was no hit in MPGs. The site you linked worked perfectly and the price was amazing. I almost bought a couple of them I cant wait to get rid of that CEL!

Glad it helped! I felt the exact same way; like why am I dealing with this on a truck that’s barely a few years old. Once I swapped it out and the CEL stayed gone, it was a huge relief. Mine’s been running fine since with no MPG change. Hopefully yours clears up for good too

 

[rclee]

Glad it helped! I felt the exact same way; like why am I dealing with this on a truck that’s barely a few years old. Once I swapped it out and the CEL stayed gone, it was a huge relief. Mine’s been running fine since with no MPG change. Hopefully yours clears up for good too

We will find out in a week, when it gets here.

The research I did it seems like almost all the ford engines uses this type of sensor. The video I watched was Ranger 2.3 eco that was having the issue. That sensor was in the rear under the brake booster. Glad ours is right on top!
Another video was a guy that was going to show you how to "FIX" that sensor with a sledge hammer. He put the sensor in a vice and smashed it to bits. Guess there is no fixing the sensor, just replacement.

 

[Darnon]

Did you ever have any of the PCM software recall updates applied? It is known that the Job 1 programming had too strict EGR tolerances which could erroneously trigger a fault.

https://www.mavericktruckclub.com/f...ue-tsb-23-2059-brakes-grabbing-removed.28255/

 

[Joaquin F]

Did you ever have any of the PCM software recall updates applied? It is known that the Job 1 programming had too strict EGR tolerances which could erroneously trigger a fault.

https://www.mavericktruckclub.com/f...ue-tsb-23-2059-brakes-grabbing-removed.28255/

Honestly I don’t specifically recall having that PCM update done, but there’s a decent chance it might have been applied at some point since my truck has been to the dealer a few times for recalls/software updates over the years.

The interesting part is the truck always drove completely normal while the code was there — no MPG loss or drivability issues. After replacing the sensor with the updated part number though, the CEL never came back.

 

[Glen Baker LLC]

Wanted to share this in case it helps someone else out. I’ve been dealing with a P0402 (EGR Flow Excessive) on my 2022 Maverick Hybrid, and I think I finally tracked it down.

Part numbers (important)

I went down the rabbit hole on this and found that Ford has updated this sensor a few times:

JX7A-5L200-AD (original / older)
JX7Z-5L200-A (updated)
RX6Z-5L200-A (current replacement)

If you’re ordering, just go straight to this one:
https://www.oemfordpartsdirect.com/oem-parts/ford-sensor-assembly-rx6z5l200a

Location
It’s on top of the engine and super easy to get to. I attached a photo of the sensor and where it sits on the motor so you can double check before ordering.

Dealer vs DIY
Dealer quoted me $260.29.
But after going back and forth with them, they were actually really cool about it and said:
“If you are somewhat mechanically inclined, yes, you should be able.”
“The part # that we are recommending is RX6Z5L200A”

So it seems like most of the cost is labor.

Quick shoutout
I appreciated that they didn’t just push the repair, helped confirm the correct part, and were honest that it’s something I could do myself.

Thank you @Joaquin F for your time, research and posting.

 

[Joaquin F]

Thank you @Joaquin F for your time, research and posting.

Of course!!

 

[MakinDoForNow]

I had my EGR valve replaced under warranty for cel with P0402. Cel came back on in couple days with P0402. Dealer then replaced the module with the sensor. Do not remember which one was replaced under the (5y60k warranty as truck was past 3y36k) and the other was covered with $100 ded extended warranty.

 

[rclee]

Hello All, I replaced the sensor that @Joaquin F recommended last week. I have been P0402 free since then! It took all of about 5 minutes to replace. 1 nut and 2 vacuum lines and 1 connector. Just don't drop the nut

@Darnon all software updates have been done. I did get a notice that there is a trailer controller recall, but I just have the hitch for 2K tow not 4k tow. I don't think that applies to my truck.

 

[MakinDoForNow]

Hello All, I replaced the sensor that @Joaquin F recommended last week. I have been P0402 free since then! It took all of about 5 minutes to replace. 1 nut and 2 vacuum lines and 1 connector. Just don't drop the nut

@Darnon all software updates have been done. I did get a notice that there is a trailer controller recall, but I just have the hitch for 2K tow not 4k tow. I don't think that applies to my truck.

It is apparently for all factory installed hitches.

 

[rclee]

It is apparently for all factory installed hitches.

Thanks, James! I will call my dealer.

 

[Joaquin F]

Hello All, I replaced the sensor that @Joaquin F recommended last week. I have been P0402 free since then! It took all of about 5 minutes to replace. 1 nut and 2 vacuum lines and 1 connector. Just don't drop the nut

@Darnon all software updates have been done. I did get a notice that there is a trailer controller recall, but I just have the hitch for 2K tow not 4k tow. I don't think that applies to my truck.

Welcome to the code free gang!

 

[icegradner]

@Darnon all software updates have been done. I did get a notice that there is a trailer controller recall, but I just have the hitch for 2K tow not 4k tow. I don't think that applies to my truck.

It shows up on the Ford recall page for my VIN, also only 2k 4pin. The software appears to be for all Mavericks with factory towing setups, regardless of rating. It does not seem to be tied to having a brake controller, since that has nothing to do with trailer lights, which is what the recall is for.

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