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1996 Ford Windstar 3.8L EGR System Fault: Fixing P1405 Code with Missing Hose and DPFE Sensor Connections

Model: Ford Windstar Fault Code: P1405 Posted: 2012-12-12 08:06

Hello! I recently encountered fault code P1405 on my 1996 Ford Windstar 3.8L, indicating an issue with the Exhaust Gas Recirculation (EGR) system. Upon inspection, I found that one of the two rubber hoses connected to the EGR sensor was missing — though there are clearly two mounting joints on the engine side. The existing hose connects to a steel pipe running from the EGR valve toward the cabin and into the engine compartment. The other connection point appears to be absent or damaged. I previously had repairs done by someone who may have overlooked this detail, leading to intermittent Check Engine light activation — it would come on and go off without any noticeable impact on fuel economy. My question: Where exactly should these two rubber hoses connect? The top elbow hose connects to the right (driver's side) port of the DPFE (Diesel Particulate Filter EGR) sensor, while the bottom elbow hose connects to the left port. This configuration is standard for most 1990s Ford Windstar models. However, after verifying my model year more closely, I realized it might actually be a 1995 model — which appears to lack an official EGR line part in catalogs like RockAuto. The sensor itself has only one open connection leading into the engine bay, and there's no visible path for EGR pressure flow. This leads me to wonder: is the EGR system left open to atmosphere? If so, how does that affect emissions compliance? Given the age of the vehicle (over 30,000 miles), I suspect one hose may have deteriorated or been improperly disconnected. The existing joint appears intact, but I'm not confident about a full visual inspection due to limited access. Any insight into whether this setup should be sealed or if it's acceptable for long-term operation would be greatly appreciated.

Related fault codes

P1405

Comments (6)

Anonymous 2012-12-12 09:28

The EGR valve typically has two elbows connecting to the exhaust manifold tube. The top elbow hose connects to the right (driver’s side) port on the DPFE sensor, and the bottom elbow hose connects to the left port. This configuration is standard for 1990s Ford Windstar models. Ensure both hoses are properly installed to maintain EGR system integrity and prevent P1405 fault codes.

Anonymous 2012-12-14 03:25

Thanks Mohaw! I checked RockAuto’s catalog for an 'EGR line' part for my 1995 model, but it doesn’t list any EGR hoses. All other emission components are available. This is puzzling because the DPFE sensor has only one open connection to the engine bay — suggesting no path for EGR pressure flow. Could this mean the system has been left open to atmosphere all along? The Check Engine light was off until recently, so I suspect it may have been operating in an unregulated state.

Anonymous 2012-12-14 08:21

No — the EGR system should never be open to atmosphere. Even on a 1995 Ford Windstar, the EGR valve has two elbows (Ford Part # 9D477) connecting it to the exhaust manifold tube. Given the vehicle's age, one elbow may have rotted or broken off, or the hose could simply be missing. I recommend checking with a Ford dealership for the correct replacement part. Once properly reinstalled, the P1405 code should resolve.

Anonymous 2012-12-14 08:47

Thanks again — I suspected as much. While I couldn’t see any visible hole or remnants of the joint during my inspection, it’s difficult to access that area thoroughly. The existing hose is in good condition, so I’ll re-inspect carefully before making any decisions.

Anonymous 2012-12-17 02:36

Yes — the upper elbow was completely cut off. I appreciate your clarification, Mohaw. A bundle of one-inch cables was hanging from that position, almost blocking the hole. It’s likely that this cable bundle has been there for at least 30,000 miles and may have been exposed to high heat. Despite this, emissions remain within legal limits — which is reassuring.

Anonymous 2012-12-17 08:57

So you’ve replaced or repaired the EGR hose? Has the P1405 code cleared after the repair?