Intermittent P0402 (2022 Hybrid)

[rclee]

Hello guys/gals my 22 Maverick Hybrid is throwing the same P0402 code. I have 54,000 miles on it. This started two weeks ago. I cleared the code with my scanner. That lasted for a couple of days then came back on. One day while I was driving it went off by itself. Now it is back The truck is running fine and the idle is smooth, so I really don't think there is an issue with a stuck EGR valve. I did some research and this seems like a common problem with quite a few Ford vehicles.

The one question I have, what is the most recent version of the DPFE sensor. The one on my Mav is JX7A-5L200-AD. I have seen other posts with RX6Z-5L200-A.

This really looks like a DYI for the average person. Heck it is right on top and easy to get to. I attached a picture of my DPFE sensor.

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[MakinDoForNow]

Hello guys/gals my 22 Maverick Hybrid is throwing the same P0402 code. I have 54,000 miles on it. This started two weeks ago. I cleared the code with my scanner. That lasted for a couple of days then came back on. One day while I was driving it went off by itself. Now it is back The truck is running fine and the idle is smooth, so I really don't think there is an issue with a stuck EGR valve. I did some research and this seems like a common problem with quite a few Ford vehicles.

The one question I have, what is the most recent version of the DPFE sensor. The one on my Mav is JX7A-5L200-AD. I have seen other posts with RX6Z-5L200-A.

This really looks like a DYI for the average person. Heck it is right on top and easy to get to. I attached a picture of my DPFE sensor.

2022 hybrid lariat 46k miles
Jan 9 2026 got p0402 replaced under extended warranty LX6Z*9D475*A EGR VALVE $100 DED
Feb 4 2026 got p0402 replaced under (5yr/60 or 80k warranty?) LX6Z*9J433*C TRANSDUCER ASSY WITH TECH COMMENT = "When tapping on DPFE sensor pid goes ERRATIC"!!!! This covered no charge.
ETA: apparently vehicle movement can cause pid bad readings???

 

[Suzukiridr14]

Ouch. $380 labor .

That's why when members ask about an ESP, I always recommend if you're keeping your Maverick for up to 7 or more years, to get a 10 year transferable ESP from Granger, just to cover the cost of labor. I feel that alone will be 250+ an hour sooner then you think.

 

[Suzukiridr14]

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.

This is why I always suggest getting a ESP from Granger. If you have a Lariat the cost for the ESP is the same as it costs for a LX, but covers lots more things that might go bad.

 

[pigsareus]

That's why when members ask about an ESP, I always recommend if you're keeping your Maverick for up to 7 or more years, to get a 10 year transferable ESP from Granger, just to cover the cost of labor. I feel that alone will be 250+ an hour sooner then you think.

yep - paid 2300 to granger in October last year right before my factory warr expired - one month later they replaced my dead original lead battery with an AGM (would have been $450 w/ labor) and I paid my $100 deductible. Better to buy it as soon as you can - it goes up in price 2x a year.

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