Intermittent P0402 (2022 Hybrid)

[SuperTongue]

Started getting a CEL back in December for code P0402 (Exhaust Gas Recirculation (EGR) Flow Excessive Detected). Just about 40k miles on the truck (of course) and not sure if this falls under the powertrain warranty or not.

Changed the engine air filter and it went away for a few weeks then came back the other day. Two actual triggers so far.

Anyone else run into this issue? I found a couple threads here but wondering if anyone else in the same boat (past the bumper to bumper mileage) went in for the same code and got any kind of coverage for it. Or a general cost for what the fix would be.

I did find a TSB related to the issue (23-2059) so maybe it's related to that. There's also 24N04 on my VIN, but that seems slightly different and doesn't mention the specific code.

Fully prepared to eat the cost but any info would be appreciated!

Edit 1/16/26:
Issue was apparently a sensor that accumulated moisture in it. See follow up post for invoice and summary:
https://www.mavericktruckclub.com/forum/threads/intermittent-p0402-2022-hybrid.77935/post-1286208

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[ShadowBlack XL440]

Started getting a CEL back in December for code P0402 (Exhaust Gas Recirculation (EGR) Flow Excessive Detected). Just about 40k miles on the truck (of course) and not sure if this falls under the powertrain warranty or not.

Changed the engine air filter and it went away for a few weeks then came back the other day. Two actual triggers so far.

Anyone else run into this issue? I found a couple threads here but wondering if anyone else in the same boat (past the bumper to bumper mileage) went in for the same code and got any kind of coverage for it. Or a general cost for what the fix would be.

I did find a TSB related to the issue (23-2059) so maybe it's related to that. There's also 24N04 on my VIN, but that seems slightly different and doesn't mention the specific code.

Fully prepared to eat the cost but any info would be appreciated!

I would think anything emission related would be covered under the factory warranty.

Google says:
Ford's emissions warranty covers essential parts for
8 years or 80,000 miles (whichever comes first), including the catalytic converter, electronic control unit, and onboard diagnostics, ensuring your vehicle meets federal standards. Other emissions-related components might fall under the shorter 2-year/24,000-mile or standard 3-year/36,000-mile New Vehicle Warranty. Specific coverage varies, so checking your owner's manual or Ford's website with your VIN is best for precise details, with hybrid/EV components often having extended coverage too

 

[SuperTongue]

I would think anything emission related would be covered under the factory warranty.

Google says:
Ford's emissions warranty covers essential parts for
8 years or 80,000 miles (whichever comes first), including the catalytic converter, electronic control unit, and onboard diagnostics, ensuring your vehicle meets federal standards. Other emissions-related components might fall under the shorter 2-year/24,000-mile or standard 3-year/36,000-mile New Vehicle Warranty. Specific coverage varies, so checking your owner's manual or Ford's website with your VIN is best for precise details, with hybrid/EV components often having extended coverage too

From what I've seen, the EGR doesn't fall under the 8/80 warranty since it's major parts only at that point unless there's specific wording saying otherwise.

 

[pigsareus]

Started getting a CEL back in December for code P0402 (Exhaust Gas Recirculation (EGR) Flow Excessive Detected). Just about 40k miles on the truck (of course) and not sure if this falls under the powertrain warranty or not.

Changed the engine air filter and it went away for a few weeks then came back the other day. Two actual triggers so far.

Anyone else run into this issue? I found a couple threads here but wondering if anyone else in the same boat (past the bumper to bumper mileage) went in for the same code and got any kind of coverage for it. Or a general cost for what the fix would be.

I did find a TSB related to the issue (23-2059) so maybe it's related to that. There's also 24N04 on my VIN, but that seems slightly different and doesn't mention the specific code.

Fully prepared to eat the cost but any info would be appreciated!

here's an older MTC thread that you might find useful : (40) EGR Issues, Replaced Two Things Now What? | MaverickTruckClub - 2022+ Ford Maverick Pickup Forum, News, Owners, Discussions

 

[jorl]

I had the same PO402 EGR code pop up(at 42,500) but went away in a day,still wanted to have it checked.I have the Granger warranty so it was covered except for $100 deductible.Never bought an extended warranty before but I figured 2022 first year model...and I am a Chevy guy.
Needless to say I am ecstatic with this truck and that was my first problem ever!

Started getting a CEL back in December for code P0402 (Exhaust Gas Recirculation (EGR) Flow Excessive Detected). Just about 40k miles on the truck (of course) and not sure if this falls under the powertrain warranty or not.

Changed the engine air filter and it went away for a few weeks then came back the other day. Two actual triggers so far.

Anyone else run into this issue? I found a couple threads here but wondering if anyone else in the same boat (past the bumper to bumper mileage) went in for the same code and got any kind of coverage for it. Or a general cost for what the fix would be.

I did find a TSB related to the issue (23-2059) so maybe it's related to that. There's also 24N04 on my VIN, but that seems slightly different and doesn't mention the specific code.

Fully prepared to eat the cost but any info would be appreciated!

 

[SuperTongue]

I had the same PO402 EGR code pop up(at 42,500) but went away in a day,still wanted to have it checked.I have the Granger warranty so it was covered except for $100 deductible.Never bought an extended warranty before but I figured 2022 first year model...and I am a Chevy guy.
Needless to say I am ecstatic with this truck and that was my first problem ever!

When you had it checked, was there actually an issue they fixed? If so, do you remember what it was? I've had this pop up twice now about a month apart and seems to only fire once then eventually goes away after a couple drives.

First time seemed pretty random, second time was immediately after I got gas. Could be a coincidence, maybe not.

Taking mine in soon so just wondering what the hit might be for the repair out of warranty (guess I should have gotten an extended one).

 

[jorl]

I think they just replaced EGR? says they replaced DPFE?-see if you can read this and figure it out -at $200/hour,I would replace myself

When you had it checked, was there actually an issue they fixed? If so, do you remember what it was? I've had this pop up twice now about a month apart and seems to only fire once then eventually goes away after a couple drives.

First time seemed pretty random, second time was immediately after I got gas. Could be a coincidence, maybe not.

Taking mine in soon so just wondering what the hit might be for the repair out of warranty (guess I should have gotten an extended one).

 

[skinnyboy]

Looks like they replaced the solenoid, $130 CAD. Probably an easy fix.

Cheers.


Egr Solenoid - Ford (LX6Z-9J433-C)
Genuine OEM Ford Parts & Accessories - lx6z9j433c

 

[Darnon]

I think they just replaced EGR? says they replaced DPFE?-see if you can read this and figure it out -at $200/hour,I would replace myself

DPFE is the sensor that measures EGR flow - differential pressure feedback electronic.

@SuperTongue have you had all of the recalls done, particularly ones like the programming for the engine failure monitor? Those would have updated the PCM which the newer versions would have incorporated the adjusted EGR values the TSB you mention encompasses; earlier versions would trigger false positives.

EGR wouldn't be a federal emissions warranty major item, but depending on build date and state CARB SULEV warranty could apply.

 

[jorl]

DPFE is the sensor that measures EGR flow - differential pressure feedback electronic.

@SuperTongue have you had all of the recalls done, particularly ones like the programming for the engine failure monitor? Those would have updated the PCM which the newer versions would have incorporated the adjusted EGR values the TSB you mention encompasses; earlier versions would trigger false positives.

EGR wouldn't be a federal emissions warranty major item, but depending on build date and state CARB SULEV warranty could apply.

so,would replacing DPFE be the same as updating PCM with new EGR values? are the 2 interchangeable?

 

[Darnon]

so,would replacing DPFE be the same as updating PCM with new EGR values? are the 2 interchangeable?

No.

 

[SuperTongue]

I think they just replaced EGR? says they replaced DPFE?-see if you can read this and figure it out -at $200/hour,I would replace myself

Thanks - hopefully it's just that but guess I'll find out. Looks like what @skinnyboy mentioned vs the actual EGR replacement.

DPFE is the sensor that measures EGR flow - differential pressure feedback electronic.

@SuperTongue have you had all of the recalls done, particularly ones like the programming for the engine failure monitor? Those would have updated the PCM which the newer versions would have incorporated the adjusted EGR values the TSB you mention encompasses; earlier versions would trigger false positives.

EGR wouldn't be a federal emissions warranty major item, but depending on build date and state CARB SULEV warranty could apply.

Yea, all recalls were done that I've had so far. So you're saying since they're all done, the TSB update wouldn't apply here? So possibly an actual sensor issue or EGR problem?

And bummer on the emissions warranty. Not in a CARB state so that also wouldn't apply.

 

[RebellaE]

I had the same error. It came and went for a few weeks, I tried changing the air filter, but that did not ultimately stop the error. Took it to the dealer hoping it would be covered by warranty or one of the Customer Satisfaction programs. Ended up needing 2 sensors replaced, about $650. I was disappointed that it was not covered under the emissions or power train warranty, I was just over my bumper to bumper mileage.

I had all recalls done long before the error popped up.

 

[jorl]

2 sensors replaced...$650 unbelievable!!! I never had any recalls done except for the undershield fire hazard

I had the same error. It came and went for a few weeks, I tried changing the air filter, but that did not ultimately stop the error. Took it to the dealer hoping it would be covered by warranty or one of the Customer Satisfaction programs. Ended up needing 2 sensors replaced, about $650. I was disappointed that it was not covered under the emissions or power train warranty, I was just over my bumper to bumper mileage.

I had all recalls done long before the error popped up.

 

[SuperTongue]

I had the same error. It came and went for a few weeks, I tried changing the air filter, but that did not ultimately stop the error. Took it to the dealer hoping it would be covered by warranty or one of the Customer Satisfaction programs. Ended up needing 2 sensors replaced, about $650. I was disappointed that it was not covered under the emissions or power train warranty, I was just over my bumper to bumper mileage.

I had all recalls done long before the error popped up.

Ugh go figure. Hopefully it won't be that much but mentally preparing myself for it. Go figure these don't pop up until right after the bumper to bumper expires.

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