It was the DPFE sensor after all. A quick replacement of the DPFE and the P0401 code cleared. I now have a P1131 code for lack of H02S-11 switch, indicates lean. I suspect the air intake gasket on the TB may have been damaged or the DPFE hoses require re-sealing around the ports off the EGR...
EGR valve fitting
I've got a P0401 (insufficient EGR flow) code on my 97 Expedition with 5.4L engine and chasing down the problem too. I'm working from cheap and easy to the more expensive and time consuming options. I Seafoamed the engine to start. Figuring that'd clean some of the TB...
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