[enginepaul]

I replaced the DPFE on my 96 4.0 and the instructions said that it may set a trouble code. (Both genuine Ford and Standard part) Phoned dealer service to see if they can reset my computer to work with the new unit but they had no idea what I was talking about. Does anyone know what to do? I am in California with smog checks and there can't be any codes to pass smog test.

 

[Astrobuf]

I replaced the DPFE on my 96 4.0 and the instructions said that it may set a trouble code. (Both genuine Ford and Standard part) Phoned dealer service to see if they can reset my computer to work with the new unit but they had no idea what I was talking about. Does anyone know what to do? I am in California with smog checks and there can't be any codes to pass smog test.

Pretty much any code reader will allow you to reset the trouble code. Go to OReilly, they will possibly loan you a reader, or use it for you to read and clear the code.

You could just buy a code reader, abt $40 for a basic device and do it yourself.

Astrobuf

 

[enginepaul]

Thank you but that isn't what I meant. The new DPFE keeps sending a fault, but the info sheet accompanying the unit says the dealer can re-program PCM. The dealers in the area charge $235 an hour and up.
Just trying to save some bucks, The first dealer I called didn't know what I was talking about and said "That's an old truck."

 

[Astrobuf]

Thank you but that isn't what I meant. The new DPFE keeps sending a fault, but the info sheet accompanying the unit says the dealer can re-program PCM. The dealers in the area charge $235 an hour and up.
Just trying to save some bucks, The first dealer I called didn't know what I was talking about and said "That's an old truck."

Ah, I get it.

Dealer techs are quite good on cars up to 4 or 5 years old, but get out of touch on vehicles much older than that.

Recognize that when you called the dealer you were not speaking to a mechanic, or even an ex mechanic. Most dealers typically hire "sales" types as seevice advisors these days. There may well be someone in the shop who knows what to do, but getting to talk to them....impossible.

There is a good relevant thread I suggest you follow.

Do you have to calibrate the EGR position sensor?

When replacing the position sensor on the EGR valve, does it need to be calibrated somehow? I had a DTC for EGR valve insufficient flow so, after some troubleshooting, I replaced the position sensor. Immediately after replacing the sensor I got EGR valve exissive flow! I cleared the code and...

www.explorerforum.com

Without voltage info it is hard to determine the source of your fault code.

I'd suggest you try the disconnect the battery for 10 min to clear the pcm.

I'd also suggest you disconnect and reconnect the sensor connector several times in case you have a poor electrical connection.

Finally, I'd check the engine for vacuum leaks. I find the Ford plastic vacuum lines get brittle with age and readily crack inside their sheath when moved much. Perhaps the vacuum line to the egr got moved too much and cracked?

I do not believe there is any reprogramming required beyond code clearing. This as I said can be done for free at OReilly's...


Astrobuf

 

[Mhanglow]

I replaced the DPFE on my 96 4.0 and the instructions said that it may set a trouble code. (Both genuine Ford and Standard part) Phoned dealer service to see if they can reset my computer to work with the new unit but they had no idea what I was talking about. Does anyone know what to do? I am in California with smog checks and there can't be any codes to pass smog test.

I would check the part number on both the pcm and the dpfe sensor. Make sure that you have the correct sensor. The correct new sensor should not cause a trouble code. I also never heard of reprogramming a pcm for a new sensor. I replaced my dpfe sensor on a 95 4.0 with no programming. Good luck.

 

[enginepaul]

First, thanks for the answers.
From a Standard Brands part, the Ford part pretty much said the same if I recall correctly:
". . . Also, be aware that the static or KOEO (key-on, engine-off) voltage reading was 0.55 volts for the aluminum body units, whereas the plastic body units are 1.0 volt. Ford has expanded the specification for this sensor to accommodate this supersession. The new specification is: 0.2 to 1.3 volts. These new voltage ranges will not set the Check Engine Light or cause performance concerns. However, they may set a trouble code when performing a KOEO test due to the old tolerance range set in the PCM. This is considered normal and should be ignored. Ford does not recommend re-flashing the PCM to eliminate this code, and it will only appear in the KOEO mode. This is not an OBD II code."
I get a 301 code but I haven't done further testing and re-testing.
As to dealerships, I know they have changed much over the years and the ones around here (Northern California) are mostly big businesses. I've known a couple of dealers and two service managers that were former mechanics I looked at the business card of the intake person where my wife took her Edge and the title is: "Lincoln Concierge" It was very different when I was young.

I'll work out my problem and if the answer may help someone, I'll post it here