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Egr sensor keeps melting - 1998 Lincoln Continental

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Excessive exhaust back pressure causes this.

Posted on Feb 15, 2012

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Egr p0401


Check vacuum lines near EGR valves.

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The hot exhaust gas is coming up thru the EGR valve.
It probably needs to be replaced with a new sensor.

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2002 Ford Escape XLS 3.0L 4WD Firewall side Catalytic gets TOO HOT and melts insides?


Replace all of the ignition coils. You will pay about $450 in parts. That will fix your problem. It fixed mine.

Jan 20, 2013 | 2002 Ford Escape

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I have a tropubleshooting code of P1405. On a ford Expedition 5.4l. Where do i fine the DPFE sensor (DPFE sensor upstream hose off or plugged.. aaECM detected EGR flow in a negative direction with aan


DPFE sensor failures are VERY COMMON on Ford vehicles. However, clogged EGR ports are also very common on 5.4L Ford engines. The DPFE sensor is located on the left side of the engine. It connects to two silicone rubber hoses that connect to the steel EGR tube coming from the back of the engine to the EGR valve. (See picture of the sensor below)

Another common failure is a DPFE sensor that has melted due to excessive exhaust back-pressure. If you find the DPFE sensor melted, suspect a restricted exhaust. (smashed tailpipe, clogged catalytic converter, etc..)


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Dec 29, 2011 | 2002 Ford Expedition

1 Answer

I washed my engine on 2002 ford escape and now it has no power and egr pressure sensor keeps blowing off or melting


YOUR REAR PRE- CATALATIC CONVERTER IN FAULTY ITS THE ONE ON THE RIGHT SIDE EXHAUST MANIFOLD BETWEEN THE ENGINE AND FIREWALL AS THE INSIDES OF IT MELTS ITS GOING TO CLOG THE REAR FULL CONVERTER AND THE ENGINE WILL LOSE POWER ALL TOGETHER BUT MOST LIKLY IDLE JUST FINE

Nov 27, 2011 | 2002 Ford Escape

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02 mercury sable egr pressure feedback sensor keeps melting on the smaller vacuum side. And keeps blowing out smaller hose. Engine is running ok at idle but will not accelerate past 20 mph. What would...


Most likely it is the catalytic converter one the firewall side clogged. the part that melts is the exhaust feedback side and it backs up the hot air once the converter is clogged. I had same problem on 03 escape. Also resist putting straight pipe on downstream converter because it catches any loose carbon from going into the muffler. If the muffler is clogged it will do the same.

Aug 12, 2011 | Mercury Sable Cars & Trucks

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My 2002 Escape started shifting badly and I smelled something melting, I looked under the hood and the EGR sensor was laying on a hot manafold, melted, and the hoses are gone and I don't know what goes...


Hi, welcome to FixYa.com my name is Shawn and I will be answering your question.

The hoses connect to the EGR pipe there are two different size connections one is smaller than the other and the hoses are two different sizes. The DPFE sensor also has a small and larger port connect all the small ends with the small hose it goes EGR tube, small hose, DPFE then do the same with the large port.

I hope my assistance helped you and resolved your concern, if you need further assistance please ask.

Aug 08, 2011 | 2002 Ford Escape

3 Answers

OBD Codes P0401; P0171; P0174. EGER valve sensor vacuum tube winds up upon starting; will not idle. What have others found to be the issue? EGR sensor has gotten very hot and plastic tube connectors have...


p0401 egr flow insufficient. p0171 system to lean ( bank 1 ). p0174 system to lean ( bank 2 ). common problems that trigger p0401--
  • Restriction in the EGR passages, usually caused by carbon buildup
  • The EGR Valve is defective
  • Lack of proper vacuum or electrical signal to the EGR valve
  • Malfunctioning EGR Vacuum supply solenoid
  • Lack of proper EGR system feedback to the computer from the:
    • Manifold Absolute Pressure Sensor (MAP)
    • Differential EGR Pressure Feedback Sensor (DPFE)
    • EGR Valve Position Sensor (EVP)
    • EGR Temperature Sensor - p0174--
    • In the vast majority of cases, simply cleaning the MAF sensor does the trick. Consult your service manual for it's location if you need help. I find it's best to take it off and spray it with electronics cleaner or brake cleaner. Make sure you are careful not to damage the MAF sensor, and make sure it's dry before reinstalling also
    • Inspect all vacuum and PCV hoses, replace if necessary
    • Check for a dirty fuel filter and proper fuel pressure p0171- and p0174 are about the same.

Mar 08, 2011 | 2000 Ford Expedition

2 Answers

PO402 trouble code....how is this repaired


Exhaust gas recirculation flow excessive. First things to check is your vacuum hoses to egr position sensor (Dpfe sensor) Egr solenoid & egr valve. If they are off, melted or sucked in they need to be replaced. Usually a specific code will be set for that but not always. Of the three the dpfe sensor also known as egr position sensor is the most common & easiest to replace. Next in order is the egr solenoid. Lastly if it comes to changing egr valve make sure to clean all carbon build up in cavity that egr mounts to. They commonly plug up.

Sep 24, 2010 | 2002 Ford Explorer Sport

2 Answers

EGR code keeps coming on


It may be, but the code will specify what the problem is as a lot of things can trigger an EGR code. There are numerous codes that relate to the EGR, but the individual code will usually pinpoint what the issue is.
Some causes could be the DPFE sensor is faulty; there is a blockage in the EGR (tube), most likely carbon buildup; the EGR valve is faulty; the EGR valve may not be opening due to a lack of vaccuum

Aug 25, 2009 | 2002 Mazda Tribute

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