P0404 on Ford: How to Diagnose & Fix
Exhaust Gas Recirculation Circuit Range/Performance
6 Ford models · 6 documented issues · 6 critical · $800-$3,500 repair
P0404 on Ford by model: symptoms, diagnosis and fix
The EGR (Exhaust Gas Recirculation) cooler on 2011-2019 6.7L Power Stroke diesel engines is prone to clogging with soot and eventually failing, particularly on trucks used for highway driving, light loads, or trucks that idle extensively. The EGR cooler recirculates cooled exhaust gas back into the intake to reduce NOx emissions. Over time, soot accumulates in the cooler's internal passages until coolant flow is restricted, causing the cooler to overheat and fail. When it fails, exhaust gases enter the coolant system, causing overheating and "puking" coolant from the degas bottle. The 2011-2014 models are particularly susceptible due to narrow internal coolant passages. Ford issued TSBs for 2011-2014 trucks covering EGR cooler cleaning/replacement under extended warranty up to 120,000 miles. The EGR cooler for 2011-2016 is OEM part BC3Z-9V425-A; 2017+ is HC3Z-9V425.
Common Symptoms
- Coolant loss with no visible external leak
- Coolant reservoir overflows or "pukes" coolant
- White smoke from exhaust (coolant in combustion)
- Engine overheating warning
- DTC codes P0401 (Insufficient EGR Flow) or P2457 (EGR Cooler Performance)
- Bubbling or foaming in coolant degas bottle
- Loss of power under load (especially towing)
- White deposits around degas bottle cap
How to Fix
Replace EGR cooler (BC3Z-9V425-A for 2011-2016; HC3Z-9V425 for 2017+). Check if truck qualifies for Ford extended service coverage with active DTC P0401 (Insufficient EGR Flow) or P2457 (EGR Cooler Performance). Some 2011-2014 trucks covered to 120,000 miles. Preventive: use a fuel additive (Diesel Kleen, Hot Shots Secret EDT) to reduce soot. Perform regular EGR cleaning at 60,000-mile intervals. Upgrade kits from Sinister Diesel and Dorman (904-405 kit) include both EGR cooler and gaskets.
Sources for this issue (1)
Ford has recalled certain 2025 Mustangs because the exhaust gas recirculation (EGR) valve may fail. When it does, the car can suffer an unexpected loss of drive power. NHTSA's concern is straightforward: losing power without warning — pulling out of a junction, merging, or in traffic — raises the risk of a crash. The campaign as a whole covers 47,804 vehicles across nine 2025 Ford and Lincoln models; that figure is campaign-wide and is not a count of Mustangs.
Common Symptoms
- Unexpected loss of drive power while driving
How to Fix
The remedy is free. A Ford dealer replaces the EGR valve at no charge to the owner under recall 26S10. Ford mailed owner notification letters on July 31, 2026, and Mustang VINs covered by this campaign became searchable on NHTSA.gov on March 4, 2026 — so you can confirm whether your specific car is included by entering your VIN at nhtsa.gov/recalls rather than waiting for the letter. Ford customer service can be reached at 1-866-436-7332.
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Open Ford dealer map in Google Maps ↗Call to confirm they service Ford vehicles and check your VIN, recall eligibility, parts availability, and appointment options.
Sources for this issue (1)
Ford is recalling certain 2025 Maverick compact pickups under campaign 26S10 for an exhaust gas recirculation (EGR) valve that may fail. Per NHTSA, the failure produces an unexpected loss of drive power, and losing power with no warning increases the risk of a crash. This is one of nine 2025 Ford and Lincoln nameplates named in the same campaign; the 47,804-unit figure NHTSA publishes is the total across all of them, not a Maverick-specific count.
Common Symptoms
- Unexpected loss of drive power
How to Fix
Free repair at a Ford dealer: the dealer replaces the EGR valve at no charge under recall 26S10. Ford began mailing owner notification letters on July 31, 2026. If you have not received one, you do not have to wait — Maverick VINs in this campaign became searchable on March 4, 2026, so enter your VIN at nhtsa.gov/recalls to see if your truck is covered. Ford customer service is 1-866-436-7332.
Find a Ford dealer
Choose to share your location for this search, or enter an area below. Your search location is sent to Google to find dealers.
Open Ford dealer map in Google Maps ↗Call to confirm they service Ford vehicles and check your VIN, recall eligibility, parts availability, and appointment options.
Sources for this issue (1)
Certain 2025 Ford Escapes are covered by Ford recall 26S10. The exhaust gas recirculation (EGR) valve may fail, and NHTSA states the failure can leave the vehicle with an unexpected loss of drive power. The safety consequence is the crash risk that comes with a vehicle unexpectedly losing power. The Escape shares this campaign with eight other 2025 Ford and Lincoln models; the 47,804 units NHTSA reports is the campaign-wide total.
Common Symptoms
- Vehicle unexpectedly loses drive power
How to Fix
Ford dealers replace the EGR valve free of charge. Schedule the free repair by giving your dealer recall number 26S10 or NHTSA campaign 26V122000. Notification letters were mailed July 31, 2026; VIN lookup for this campaign went live March 4, 2026, so you can verify coverage immediately at nhtsa.gov/recalls. Questions to Ford: 1-866-436-7332.
Find a Ford dealer
Choose to share your location for this search, or enter an area below. Your search location is sent to Google to find dealers.
Open Ford dealer map in Google Maps ↗Call to confirm they service Ford vehicles and check your VIN, recall eligibility, parts availability, and appointment options.
Sources for this issue (1)
On 2025 Bronco Sport models with the 2.0L EcoBoost engine, the exhaust gas recirculation (EGR) valve can fail, leading to weak acceleration, engine vibration, a no-start condition, or an unexpected loss of motive power (typically at low speeds around 15 mph or below). Ford recalled roughly 12,860 Bronco Sports built 11/15/24-5/7/25 as part of a ~48,000-vehicle multi-line EcoBoost campaign and advised affected owners not to drive until repaired.
Common Symptoms
- Weak or sluggish acceleration
- Engine vibration or rough running
- No-start condition
- Sudden loss of drive power at low speed
- Check engine / powertrain warning light
How to Fix
Covered under Ford recall 26S10 / NHTSA 26V122. Interim owner letters were mailed March 20, 2026; the final remedy is still under development (anticipated September 2026), at which point Ford will repair/replace the EGR valve free of charge at a dealer. Owners should check VIN status on NHTSA.gov and follow do-not-drive guidance until the fix is available.
Sources for this issue (1)
2025 Ford Ranger pickups are among the vehicles included in Ford safety recall 26S10. The defect is a failure of the exhaust gas recirculation (EGR) valve, and the result described by NHTSA is an unexpected loss of drive power. For a truck that may be towing, hauling, or working off-pavement, losing motive power without warning is a crash risk, which is why NHTSA classifies this as a safety defect rather than an emissions-only concern. The recall population is 47,804 vehicles across the whole campaign, which also sweeps in several other 2025 Ford and Lincoln models — that number is not specific to the Ranger.
Common Symptoms
- Sudden, unexpected loss of drive power
How to Fix
Dealers replace the EGR valve free of charge. Take the truck to any Ford dealer and reference recall 26S10 (NHTSA 26V122000); there is no cost to the owner. Owner letters went out July 31, 2026, but affected VINs have been searchable since March 4, 2026 — check yours at nhtsa.gov/recalls. Ford customer service: 1-866-436-7332.
Sources for this issue (1)
P0404 code reference
General diagnostic-code context. The code alone does not confirm a cause for your vehicle; use the applicable issue card and its sources.
Frequently asked questions
What does P0404 mean on a Ford?
P0404 stands for "Exhaust Gas Recirculation Circuit Range/Performance." This code means the exhaust gas recirculation (EGR) system isn't performing within its expected range. The EGR valve routes a metered amount of exhaust gas back into the intake to lower combustion temperatures and reduce nitrogen-oxide emissions, and the computer monitors the valve's actual position versus what it commanded. When the valve sticks, moves incorrectly, or the feedback doesn't match the command, P0404 sets. This can cause rough idle, hesitation, pinging, and increased emissions. On Ford it is documented across 6 models: F-250 Super Duty, Mustang, Maverick, Escape, Bronco Sport, Ranger.
What are the most common causes of P0404?
The most common causes of P0404 are: Carbon buildup clogging the EGR valve or passages, Sticking or failed EGR valve, Faulty EGR position sensor, Corroded or loose EGR connector, Damaged or shorted EGR wiring, Vacuum leak or failed vacuum control (on vacuum-operated systems), Clogged EGR cooler or tubes, Faulty PCM/ECM (rare). The specific cause varies by vehicle.
How much does it cost to fix P0404 on a Ford?
Published repair estimates on Ford range from $800 to $3,500 depending on the model and root cause. If an issue mentions a recall or campaign, check your VIN with the manufacturer or NHTSA and confirm eligibility and coverage with a dealer.
Looking for P0404 on a different make?
View P0404 across all makes →Content compiled with AI assistance using NHTSA complaints, TSBs, and owner reports. May contain errors. Always verify with your vehicle's service manual.