P040D EGR temp sensor#1 Transit diesel - Diesel Forum - TheDieselStop.com
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post #1 of 6 (permalink) Old 08-05-2015, 09:08 AM Thread Starter
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P040D EGR temp sensor#1 Transit diesel

Had this code come up on our Transit last week. It had low power (not limp mode, just low) and it went through a tank of DEF in about 1000 miles. I had researched the code here and found that on the 6.4L, when they threw this code, the #1 EGR temp sensor was replaced per TSB. I checked with the parts dealer to see if they had one or when they could have one and since our warranty appointment was far enough away, I ordered one and left it there for the tech to install if they needed it.

Well, he got in there and checked the resistance and found it was at 1.789K Ohms, so they got the one I ordered and installed it and now Baby is back. I don't know what the range is supposed to be but 1.789K ohms was too much.

Anyway, I'm not concerned about it failing again because anything that runs through their shop gets a 2 year, unlimited mileage warranty. For us, that will be over 200,000 miles.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.
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post #2 of 6 (permalink) Old 01-18-2016, 06:48 AM
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I had the same issue at 85000 miles on mine and it took around 7 to 8 days to get the part which for me was over 2000 miles . Engine still run ok just did not accelerate well and like you the DEF fluid consumption went up drastically .
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post #3 of 6 (permalink) Old 03-21-2016, 06:56 PM Thread Starter
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She's back. 120,000 miles and I got the same code. Now it's on national back order. I'm glad I posted this here since I had forgotten about the increased DEF consumption. I will certainly park it until we can get it in.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.
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post #4 of 6 (permalink) Old 06-05-2016, 09:55 AM
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Failed sensor must not see hot egr and compensate by increasing def trying to clean exhaust that doesn't need cleaned.
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post #5 of 6 (permalink) Old 03-30-2017, 07:12 PM
AlH
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Got the P040D code yesterday shortly after I noticed power seemed down.
Made a few stops on the way home and everytime I shut down the engine acted like it would tear the motor mounts out...

Located and tested the EGR #1 sensor and it checked good at room temp.*
Turns out Ford has a late 2016 TSB saying if that code shows up don't bother troubleshooting farther- just replace the sensor.
Have 3 Ford dealers here and none had one in stock...supposed to be here tomorrow.
BTW the part number given in the TSB is slightly different and it is MUCH cheaper than the original part number- $37

One thing that gave me a lot of trouble was getting the sensor unscrewed from the exhaust manifold, liberal application of Kroil and heating/cooling cycles with a torch I finally broke it loose. Even so be prepared to pull on the wrench with all you have.
You will need a 17mm flare wrench- you'll round it off with an open end and can't get a box end on it unless you are willing to disassemble the connector or cut the wire.
Ford service info says to put nickel antisieze on the threads of a new one- but I can see they did NOT use any on the original build. Probably would have come loose a lot easier if they had!


*So since I had the suspect sensor out I decided to test it. Resistance is about 250 ohms at room temp, goes down when put on ice and goes up when heated....BUT heating it beyond a certain point with a butane lighter it goes OPEN. Which is what the P040D basically says is wrong.

Added in edit> Sensor in/code gone. New one looks different and it appears the nut may be stainless where the old looks like it wasn't. Made in Bulgaria

96 F350 CrewCab BTS-E4OD 4.10 4x4 / Banks Git-Kit / 99-Intercooler / 00 FourWheelCamper Pop-up
2015 Transit T350HD 3.2D- totalled- replaced with 2018 Transit T350HD 3.5 GTDI

Last edited by AlH; 03-31-2017 at 10:01 AM. Reason: Added Info
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post #6 of 6 (permalink) Old 04-02-2017, 07:18 PM Thread Starter
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Great info on that. Thanks for adding what you found was going on with the heat resistance test.
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