I’m not exactly sure what specifically changed on the 2022+ truck. I’ve been told that the injectors are different (but have no proof of that), and I do know there are two different versions of the MAF floating around (Germany and China sourced) There have been a number of DPF’s with internal failures of various kinds. STAR sent out a follow up report to one of the techs (who then shared it with me) that lists several things to look at. I can’t remember if I already posted this here but will post again below for the sake of clarity. My truck worked flawlessly from January 2023 when I started documenting my regen cycles. Regenerations were all on the 24 hour timer, with minimal or no noticeable soot buildup on the dash gauge. Mileage was between 900-1000 miles between each regen. This behavior continued until June 2023. After which it spent the next five months (End of June to end of October) running regeneration cycles at half the previous time and mileage interval. Anywhere from 6-18 hours and roughly 200-500 miles between regens. Out of nowhere, the behavior rectified itself at the end of October 2023. At the time, I had just switched where I buy my fuel and also stopped using hotshots edt fuel additive. I had thought that this action was the driving factor behind the improvement in regen performance, however now I’m not so sure. The truck worked flawlessly from the end of October 2023 until about the end of March 2024. Again, all regens at the 24 hour mark and no noticeable soot accumulated on the DPF gauge. Starting in April 2024, I noticed a
very sudden increase in soot loading, and a significant reduction in noticeable passive regeneration.
Its important to note that, throughout the course of my documentation, the trucks’ duty cycles, speeds, routes, fuel source, operator, etc all remained identical. There were no significant outliers in how the truck was used, and save for a few isolated occasions, was operated almost exclusively on the highway, in an unloaded / non-towing scenario, while maintaining a speed of 75mph consistently as much as possible. As April began, I noticed soot would accumulate much faster, and would not passively regenerate out like it had previously done for the past 7 months. This behavior resulted in the regeneration cycles moving significantly closer together in both time and mileage. My next to last regeneration cycle was pushed out to the 24 hour mark only because I had a significant amount of heavy towing to do, and this use was what reduced the soot load enough to stretch the time interval out to the 24 hour mark. Had it not been for the towing, the regen cycle would have initiated at roughly 400-500 miles and about 12-14 engine hours. My most recent regeneration was at 502 miles and 14 hours, approximately half the interval that the truck had previously been able to achieve under the same style of operation for multiple months.
As of this writing, I am 90 miles since my most recent regeneration and is already showing 25% soot load on the in-dash DPF gauge. If this trend continues, I will be lucky to reach 200 miles this interval before the truck goes into regen again.
It’s also important to note that I monitor my DPF gauge very closely and use that to anticipate when regen cycles will trigger. I typically adjust my driving so that the regen occurs on the highway will traveling at 70+ mph and I allow the cycle to complete 99% of the time. Typically takes about 20-30 minutes depending on soot load.
As of right now, i believe this issue may be related to the change in temperature and weather. My theory is that the MAF sensor may not be adapting sufficiently to environmental changes. This may be either because the MAF itself might be faulty, or my drive cycles are not providing sufficient time and data to make adaptation possible. I’m going to attempt the adaptation relearn procedure mentioned below in the coming days. If that is not successful I may attempt to buy the updated part number MAF and then perform the relearn again. As always I will report back. View attachment 72743View attachment 72744