Thats a boogers!,If it were mine, i would try jb weld first, it may be just a casting void- if not, find a junk yard and pull another!
Like my dad STILL says: you have everything to gain and nothing to lose!

 

I'd what RC says and hit the junk yard. You can get one from RockAuto but it's $183. As for JB Weld "J-B Weld can withstand a constant temperature of 500 °F (260 °C), and the maximum temperature threshold is approximately 600 °F (316 °C) for 10 minutes. J-B Weld can also be used inside a microwave oven, exposed to microwave radiation instead of infrared radiation (heat)."

 

So you poked a hole in it? and Shot it with a BB gun ?? Or did I read too fast..

 

I checked the booger hole like rc called it and it was the size of a pin hole after JB weld. I went with it and put the intake and TB back on. After 10 miles down the road the SERVICE ENGINE SOON light came back on......bummer ! So I replaced the only thing left that I haven't replaced yet and bought a new EVR. Put it on tonight, cleared any codes it may have had and I am going to test drive it tomorrow about 60 miles and we'll see how it goes and if I make it back home. Updates later

 

Sometimes I feel more like blowing it up with dynamite but the truck will be good to bang it scratch it dent it around without worrying about it. Just hope the service engine soon light doesn't come back on. Doesn't it usually need about 2 run cycles before it clears itself? I think I read that here somewhere.....

 

Well...don't get your hopes up. Yea dirty ports have nothing to do with the way she runs on this side of the EGR...not that you'll notice anyway. What will happen, - your mileage will increase a little with a fully functional EGR system. The PO401 will disappear as those dirty ports triggered that DTC. If you recall, I mentioned early about the 401 having nothing to do with how it runs..."0". Won't affect idle either. The EGR system will become functional again.

But yea, not the problem.

For the quickest understanding, like a crash course on these systems. You can read a bit here, -

It's not wordy and get's right to it, -

http://www.fordscorpio.co.uk/egrmonitor.htm

 

Finally took the truck to dealer because code was still showing up. Verdict: Bad DPFE sensor that I had already replaced. Good so far

 

Glad to hear! Thanks for the feedback!- you just might have helped someone fix their truck who is less fortunate than you.

 

You're so right rc.....That's what this great forum is all about. Helping others solve their problems just as I was helped narrow down what was wrong with my situation. Hope this helps others and Thanks to all here on this forum that helped along the way.

 

Yep, those are the only two outcomes for the 401. Dirty/plugged ports or a bad DPFE.