P0404 on Ford
Exhaust Gas Recirculation Circuit Range/Performance
P0404 on Ford vehicles indicates exhaust gas recirculation circuit range/performance. Au7o has documented this code across 8 Ford models — most commonly on Bronco Sport, Escape, Explorer. 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. Typical repair costs on Ford range from $300 to $3,500, depending on the specific model and root cause.
Common Causes of P0404
- •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)
P0404 on Ford by Model
Ford Bronco Sport(1 issue)
- EGR Valve Failure Causing Loss of Drive Power (Recall 26S10 / NHTSA 26V122)2025
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.
Ford Escape(1 issue)
- EGR Valve Failure — Unexpected Loss of Drive Power (Recall 26S10 / NHTSA 26V122000)2025
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.
Ford Explorer(1 issue)
- 360-Degree / Rearview Camera System Failure2020-2024
A software failure in the 360-degree camera system's image processing module can cause the rearview camera to display a blank/black image when the vehicle is placed in reverse, or the image may remain frozen on the display after the backing event has ended. This affects driver visibility and increases the risk of backing collisions.
Ford F-150(1 issue)
- Driveshaft Carrier Bearing Failure2015-2020
The two-piece driveshaft uses a center support (carrier) bearing that can wear out, causing vibration and noise. The rubber support degrades over time, especially in hot climates or with heavy towing. Ford TSB addresses this issue.
Ford F-250 Super Duty(1 issue)
- 6.7L Power Stroke EGR Cooler Clogging and Failure2011-2019
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.
Ford Maverick(2 issues)
- 12V Battery Drain and Loss of Drive Power - Recall 24S24 + SSM 530872022-2024
Ford Maverick trucks from 2022-2024 are affected by multiple 12V battery-related issues. Ford Safety Recall 24S24 (NHTSA 24V267) covers the BCM/PCM software inability to detect declining 12V battery performance, leading to Auto Start-Stop failures and vehicle stalling at low speeds. Additionally, Ford issued SSM (Special Service Message) 53087 for select 2022-2024 Maverick hybrids where the 12V battery drains intermittently when the ignition is turned off. MaverickTruckClub.com documents owners receiving "Remote Access disabled to reserve battery" FordPass alerts, with some needing 3+ battery replacements in 2-3 years. The hybrid system's complex 12V management appears to be the root cause of accelerated battery degradation.
- Recall 26S10: EGR Valve Failure Can Cut Drive Power on 2025 Maverick2025
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.
Ford Mustang(1 issue)
- EGR Valve Failure Causing Sudden Loss of Drive Power (Recall 26S10 / NHTSA 26V122000)2025
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.
Ford Ranger(1 issue)
- EGR Valve May Fail and Cause Unexpected Loss of Drive Power (Recall 26S10 / NHTSA 26V122000)2025
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.
Looking for P0404 on a different make?
View P0404 across all makes →Frequently Asked Questions
What does P0404 mean on 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 specifically, this code is documented across 8 models.
What causes P0404 on Ford vehicles?▼
Common causes on Ford: 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. Specific causes vary by model and year — see the per-model sections below.
How much does it cost to fix P0404 on a Ford?▼
Repair costs on Ford range from $300 to $3,500, depending on the specific model and root cause.
Which Ford models have P0404 documented?▼
Au7o has documented P0404 on 8 Ford models: Bronco Sport, Escape, Explorer, F-150, F-250 Super Duty, Maverick, Mustang, Ranger.