2003 Ford Expedition stalling issue with B2900 error code

Hi all. I want to apologize up front as this is going to be a long post in order to provide full context of my issue(s). I have a 2003 Ford Expedition XLT, 4x4 with a 5.4L engine. It has approximately 210,750 miles on it.

Prior to September, the truck was running great with no issues. In mid September, I was working to resolve a 1406 error code; I replaced the DPFE sensor and hoses and shortly thereafter got P0401 (Exhaust gas recirculation low insufficient) error code. I replaced the EGR valve, but it did not resolve the error code. In late September my vehicle randomly shut off while driving. I was able to get it restarted (while still moving) and drove 5 more miles before it shut off again. At this point, I had power, but the starter wouldn't engage. Not knowing what might be wrong and not being close to home, I had it towed to a Ford dealership who advised my battery and alternator needed replaced (I was not having charging or starting issues prior to this and had replaced my alternator in July). I had the repair completed and drove the truck home.

Three days later, it shut off again while driving and the check engine light came on. I was able to get it started and drove it home. I used my scan tool and pulled the following codes - B2900 (Vehicle Identification Number Mismatch), C1805 (PCM and/or ABS Module mismatch), U1262 (Standard Communication Protocol Communications Bus Malfunction), U1073 (Engine Coolant Temperature Signal Missing), P1000 (On Board Diagnostics II Monitor/Drive Cycle Test Not Complete), P0401 (Exhaust gas recirculation low insufficient), C1233 (Wheel Speed Left Front Input Signal Missing) and C1234 (Wheel Speed Right Front Input Signal Missing). When I did some online research I found that B2900 combined with C1805 and U1262 were usually early warning signs of PCM failure. I bought a PCM from a company online; cleared the codes and drove the truck for a few days with no further issues while awaiting the new part

I installed the part and had my keys re-coded by a locksmith and immediately had 'Check Engine' and 'ABS' lights on and my traction control light in the center console was on. I drove the truck back home and once again used my scan tool and pulled the following codes - B2900 (Vehicle Identification Number Mismatch), P1000 (On Board Diagnostics II Monitor/Drive Cycle Test Not Complete), B1601 (PATS Recd Incorrect Ign Key Code From Transponder), and P0602 (Powertrain Control Module Programming Malfunction). I figured the P1000 and B1601 were a result of unhooking the battery before I installed the new PCM and having my old keys in the ignition while being programmed by the locksmith to the new PCM. I was at a loss for having another B2900 error code.

I sent the defective part back to the company and bought another PCM from a different company. I installed the part yesterday and drove 15-20 miles with no issues. However, my wife drove it this morning and the 'Check Engine' light is back on with the following error codes - B2900 (Vehicle Identification Number Mismatch), P1000 (On Board Diagnostics II Monitor/Drive Cycle Test Not Complete) and P0401 (Exhaust gas recirculation low insufficient).

At this point, I am looking for suggestions on what might be causing this to continue before I take my truck to my local mechanic.

Do you still have the original PCM and keys ? Sounds like the B2900 code and all your other wheel/brake related codes are more often related to a failing ABS module. The EGR low flow issue can also be clogged EGR passages in the throttle-body elbow, especially by the 200k mile mark. There's some videos on pulling it off and cleaning out the passages on Youtube. I know Ford's IDS software will get into the VIN programming to each module. It's hard to find shops other than the dealer that actually have the IDS program and can do it right.

Hamfisted said:

Do you still have the original PCM and keys ? Sounds like the B2900 code and all your other wheel/brake related codes are more often related to a failing ABS module. The EGR low flow issue can also be clogged EGR passages in the throttle-body elbow, especially by the 200k mile mark. There's some videos on pulling it off and cleaning out the passages on Youtube. I know Ford's IDS software will get into the VIN programming to each module. It's hard to find shops other than the dealer that actually have the IDS program and can do it right.

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I do still have the original PCM and keys; however, my original keys were re-programmed to the first PCM I bought to try and solve the problem.

Prior to the vehicle randomly shutting off in September I was not having any problems with regard to wheel speed sensors or the ABS system. I thought the codes I received after the random stalling were related to the PCM and that is why I went that route.

I did not (and still do not) have a 'ABS' light on; it only came on with the defective PCM I installed to replace my original one.

If I were to buy a new ABS module, would it need to be programmed with the VIN and vehicle build information?

I made an appointment with my local mechanic for next week as I was at my wits end with regard to these electrical systems.

I will have them check/clean the throttle body while it is there as I have no doubt you are correct in that it is gunked up after more than 210K miles of driving.

We bought it in 2007 with a little over 32K miles on it. I want to get this squared away as my goal is to get 300K miles out of this Expedition. However, if it is going to start costing me more money that it is worth, I will trade it in on a newer one with less miles.

Yesterday, I was looking at a 2012 Expedition EL (Limited) with a little over 45K miles.

Really the PCM is programmed to accept the keys, not the other way around.
Do you have Forscan and a laptop ? You can look at PCM related PIDs and see what signals it's getting and if anything seems erratic (like power signal, crankshaft signal, etc...).
I'm guessing that your original keys will still work with your original PCM if nobody wiped the PCM. But you can reprogram all that with ForScan anyway.

https://forscan.org/download.html

Honestly, the only time ive seen issues like this is due to a failing battery. If you've just had this replaced, Id look for shorts in the harnes or for bad grounds.
Everything about this smells like an intermittent electrical issue - and as we all know, these Expy's love their rust. Especially on the frame rails.

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Grounds grounds grounds. Check those first. No charging and a buttload of pcm codes is a good indicator. Pay close attention to the cable from the battery to the body.

Low egr flow should not cause stalling.

My stalling was a combination of both cabling (starter, battery, fusible link, terminals) and DPFE sensor. After all connections, cables replaced it still stalled. Very unnerving when rolling on the road/freeway and it cuts out. The last fix was my faulty aftermarket DPFE sensor from Amazon. I had them put a new OEM one in and I have been trouble free for months.

In the process of working to solve the stalling, I also replaced the EGR valve and the 2 hoses and the SJB (used) so when finances allow I'll go for the upgraded SJB.

Unsure what would really cause this but after the dealer dialed it in (did also involve PCM programming) I swear my truck sounds way better and is more responsive.

GL.

Just wanted to leave a follow-up to my initial post. My local mechanic checked the vehicle over and advised the EGR valve was working as intended and recommended I take my Expedition to my local Ford dealership.

I provided my dealership a breakdown of when the initial issue started and everything I've been dealing with since.

The technician determined the DPFE sensor I replaced was the root cause. The voltage never changed, regardless of engine speed it indicated the vehicle was at idle.

They replaced the DPFE sensor with a Motorcraft part and my Expedition is running like it did before.

If anyone ever gets a P1406 or P1408 error code, replace your DPFE sensor with a Ford part and save yourself a lot of hassle.

The DPFE was the last thing that corrected my stalling.

I feel good still to have all new cables, solid terminals, new battery and and well used SJB.

Appreciate the update.