Yup its time for its 2nd DPFE in about a year...yay.
Has anyone found out a fix for this problem other replacing the sensor over and over?

 

You can get a programmer and have the EGR tuned off.

 

Have you been replacing with an aluminum one or a plastic one?

 

^ ?

Ford updated the aluminum to plastic ones, because the aluminum ones get corrosion internally which causes them to go bad. If you have a plastic one something else might be causing them to go bad somehow.

 

That's what I was meaning. There are quite a few aftermarket companies who just rebox old OE parts... wherever he may be buying the replacements from could be still selling the aluminum ones.

 

There the plastic ones. I went with the plastic one from motorcraft this time instead of the aftermarket. We will see if its any better.

 

Well the same code came back. Took the new dpfe back to orileys and traded it for another new one to see if the part was bad but the code came back again. Any suggestions. I am currently taking out the egr and the tubes to check for clogs and clean them.

 

question are they making you test only down there?

its pissing me off up here, EVERY SINGLE TIME they test only our stuff even though its not that old, yet my friend has a 2000 subaru (1 year newer than my truck) and gets to do the regular *** cheap smog

 

Yup they make us test everything here.The only thing they don't do is the visual or the leak test because the truck is newer than 2000

 

The easiest way to fix is move out of cali

 

I got the same issue. Replaced DPFE sensor "plastic one" lasted for about 6 months and now cel is back. If you find a perm fix let me know.

 

Well after replacing this dpfe sensor three times within a week and a new vacum sylinoid my cel still turns on giving me the same 0401 code. I have a new egr and am hesitant to put it in because the old one still seems to open and close when put to the vacum pump. Having said all that it seems like I am not getting but very little suction from the egr vacum line. Can someone tell me what to do next...I need to pass smog so I can get my tags.

 

I replaced the dpfe sensor again and cel was still on. I found that the plug or connector was faulty/not getting a good conection so I ziptied it on and cel has not came back on since. Both scanguage and my hand held oboII tester show no codes. Might want to check the connection.

 

I have had the same problem about every 30-50,000 miles. Found this video that explains the symptoms and fixes very well. ; http://www.youtube.com/watch?v=Ev1-kEZL3qQ
Hope it helps!
It appears to be a very common problem mine was a plugged up differential tube some carbon would get sucked up into the tube and cause the P0401 cleaned it with carb cleaner seems to be working much better still using the same DPFE valve. I am driving to Phoenix int eh morning from Lancaster, CA. It should let me know if it fixes the problem.
If not Autozone has a new valve for$30.00 if I have to I'll pick one up on the road.

 

Just got back from Phoenix, no problems with egr or any codes. Total driving was over 1000 miles so it wasn't the dpfe sensor but a clogged tube or balance port. Cleaned with carb cleaner and re-assembled.
Good luck!

 

good info to know for the future when i have to get mine smoged anyone know if my 2.3 duratec uses the same system