I had rough running and a P0401 code indicating an EGR valve problem. There is NO separate DPFE on an '05 despite the recommendations in many forums that you replace the DPFE first. There's an EGR systems module (ESM) that incorporates a DPFE. I got the Motorcraft EGR valve (part # CX-2102) from Amazon for $101.
Ford Explorers last somewhere between 100k and 200k miles. Some last for 115k, while others make it 200k, especially older models. Several maintenance issues make a Ford Explorer less likely to last longer with a few specific years, and all of this contributes to the vehicle’s lifespan. Each Ford Explorer has a few different things that can Common 4.6 Ford Engine Problems 2002 Ford F-150: Reported Engine Fires NHTSA Complaint IDs: 11171391, 11194582. While Ford’s 4.6L V8 engine saw a lot of success and popularity, it was not without its flaws. Multiple recalls were issued on the engine in its earlier years, and many complaints have been filed regarding this engine that have not

People try to quiet it down by running thicker oil, thinking the noise is due to low pressure in a high mileage motor. Only makes the problem worse! The best way to buy one with a good OHV motor is to hear it start when the engine/oil is cold. If there is rocker clatter at idle after the engine starts, you will know the cause.

The 4.0 engine is a DOHC (double overhead camshaft) design with four valves per cylinder. The bore and stroke of the 4.0 engine is 3.94 inches (100mm) and 3.27 inches (83mm), respectively. The compression ratio of the NA version of the 4.0 engine is 9:1, while the turbocharged version has a compression ratio of 8:1.
1. City, State. DODGE CITY. Year, Model & Trim Level. 1999 FORD EXPLORER 4.0. January 30, 2019. #3. 410Fortune said: crankshaft position sensor on the front of the engine is known for going out and causing a no spark condition. . 270 127 52 261 101 130 195 76 253

ford explorer 4.0 engine problems