Greetings,

I'm helping out a friend with a 2004 Freestar. At a stoplight in gear the van will run rough and surge. The check engine light came on and the error code is P0402 EGR Flow Excessive.

I did search the Freestar section of the Forum for these faults and came up ziltch.

I really don't want to just start changing components so if anyone can help me with further troubleshooting or better yet, a simple solution, it would be a great help.

Thanks in advance

George

 

Sounds like the EGR valve is hung partially or fully open. Being a 2004 with probably 80-100K miles on it, time has probably carboned the valve up.The easiest and cheapest thing to do would be to remove the EGR/DPFE assembly and clean the EGR valve as much as possible. Also make sure that the valve operates freely. Then reset he code and start fresh.

 

Had P0402 on my 2008 Escape 3.0L V6. Ran rough at idle. Disconnected the vacuum from the EGR while at idle and it smoothed out. Shouldn't have vacuum at idle, so they say. So I replaced the EGR vacuum modulator, 911-128. Just follow the vacuum line to it, next to the firewall. Ordered the part from Amazon but the $21 Chinese part was defective so I replaced it with a $60 motocraft and it works fine. I cleared the code then drove it for 30 miles to reset the sensors and it passed the smog check.

 

I have a code U1059 that the ABS circuit is not communicating with the instrument cluster. Any ideas what specific problem that could be?