P0403 Exhaust Gas Recirculation Mal-function

SOURCE: code p0401-exhaust gas recirculation flow insufficient detcted

these vehicles as well as every other Ford vehicle has had problems with the DPFE sensors going bad. Ford had a program for this problem but was limited to time and mileage. You can contact a dealer to see if it still qualifies if not the sensor will need replacement. this is very easy to replace

SOURCE: Check Engine Light On-OBD reads two codes P1405 & P0401

It is located on the right front valve cover area. It will be either black or silver and have a 3 wire connector with wire colors BN/WH,GY/RD,BN/LG. It will have 2 rubber hoses going from it and connecting to two metal tubes which run to the exhaust.

Now what sets the the P1405 is.
While driving, the EGR monitor commands the EGR valve closed and checks the differential pressure across the EGR orifice. The test fails when the signal from the DPF EGR sensor indicates EGR flow is in the negative direction. Make sure both of the hoses are hooked up and not damaged.
P0401 sets when:
The EGR system is monitored during steady state driving conditions while the EGR is commanded on. The test fails when the signal from the DPF EGR sensor indicates that EGR flow is less than the desired minimum.
So the DPFE could be causing both codes.
I would also recommend that you take a hand vacuum pump and pump vacuum on the EGR while engine is running and make sure you have a drop in RPM so you know that the EGR ports are not stopped up,they are bad about this too.
As far as the rattling converters this could possibly have an effect because it does use exhaust back-pressure along with vacuum to help open the EGR but if the exhaust is still basically stock this probably won't have enough effect on the back pressure to cause this unless they have stopped up and have so much back pressure it is blowing the hoses off of the DPFE or getting so hot it melts them. You can check this with a vacuum/pressure gage, just hook it into one of the hoses from the DPFE and you should have 1 PSI at idle and 3 to 4 PSI at wide open throttle. Anything more would be a restriction.
If all of this is ok then replace the DPFE.

SOURCE: how to replace an oxygen sensor bank 1 and exhaust gas recirculation sensor

The EGR valve is attached to the intake manifold near the throttle body and the 1/1 O2 sensor is on the rear exhaust manifold.

SOURCE: Exhaust gas component related malfunction light.

You will have to read the codes and see specifically what the problem is. Sometimes its more then one code. So its real simple to do. So just get a peice of wire maybe and inch long, bend it like a horse shoe. Then find the little jumper box,its usually on the fire wall. So in the manual find the the 2 plug in points. Thats in the emissions section. Then sit in the car and turn the key on do not start the car. and watch the blinking engine light. count the blinks and compare them in the manual. You now know the specific problem

SOURCE: exhaust pipe glows red.

clogged cat converters.