I have the same code that did appear sometime after I installed a K&N intake system. What's the relation??

 

i had this code for a while my EGR ports were pluged. i know you said yours are clean maybe your EGR tube is packed full of crap? ive seen it happen. did the same thing to my buddys 98 F-150 with a 5.4. we cleaned the ports replaced EGR and DPFE nothing then we changed the tube and the code went away.

 

Reflash would be the dealer accessing the PCM and resetting/reprograming it to get rid of the code.
I would first go through the procedure as described in the shop manual to varify the problem really isn't a problem.

 

I hope that's not too expensive. I will check the egr tube to make sure it is clean inside. Could an exhaust manifold leak cause this problem with the code?

 

Wondering what sensor(s) in the system would signal the PCM that there is excessive EGR flow. I believe that is the job of the DPFE, to measure and control EGR flow. But what else could it be. Torkum said to look for a corroded thru EGR pipe, good thought, reported all was good. What else will relate to excessive EGR flow if none exists? Thread starter asked about an exhaust leak, well why not? Could it be passing exhaust gasses before the infamous 02 sensor measures the oxygen content. Need some help here gurus.

 

What are the odds that I got a bad DPFE sensor even though it was an OEM part? Bad O2 sensor(s)?