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Automatic Regen too often

Possible fix if anyone is having issues with their dealers still, TSB - 25-005-24 dated September 27, 2024. Have your dealers check, and if you’re having this issue and you’re within the warranty they will replace DPF.
My suspicion / prediction is that this TSB will get expanded / revised as time moves forward. The DPF replacement has been attempted multiple times on multiple trucks and only has a marginal success rate at best. The problem lies deeper. Software, tuning, calibration, etc.

@Brutal_HO what are your thoughts on a merged thread? I’m still a little green with some of this, but there are several regen threads that have a substantial amount of followers and information. Might be good to get them all into one place?
 
My suspicion / prediction is that this TSB will get expanded / revised as time moves forward. The DPF replacement has been attempted multiple times on multiple trucks and only has a marginal success rate at best. The problem lies deeper. Software, tuning, calibration, etc.
They'll have it solved just about the time everyone's emissions warranty expires.
 
They'll have it solved just about the time everyone's emissions warranty expires.
I think that is the goal cost mitigation and no concern with a proper resolution. Notice the usual RamCares response is staying away from this thread.

With cooler temps (below 60 or so) i see no soot load and on longer drives good passive regen. a soon as temps are over 65 mid day I see soot loading. This has me believing it has to due with the tuning of the system. However, I believe they do not want to invest in testing and tuning to correct this and rather throw parts at people that pay attention to their trucks (small minority in the grand scheme of production).

I do wonder and may reach out to PPEI or Calibrated ( Kory of PPEI claims he can emission delete tune cleaner than factory emission tune) to see if it may resolve by running a custom tune. Those with emission compliant tunes I would love to hear what they are experiencing with the tunes and regen rates.
 
I think that is the goal cost mitigation and no concern with a proper resolution. Notice the usual RamCares response is staying away from this thread.

With cooler temps (below 60 or so) i see no soot load and on longer drives good passive regen. a soon as temps are over 65 mid day I see soot loading. This has me believing it has to due with the tuning of the system. However, I believe they do not want to invest in testing and tuning to correct this and rather throw parts at people that pay attention to their trucks (small minority in the grand scheme of production).

I do wonder and may reach out to PPEI or Calibrated ( Kory of PPEI claims he can emission delete tune cleaner than factory emission tune) to see if it may resolve by running a custom tune. Those with emission compliant tunes I would love to hear what they are experiencing with the tunes and regen rates.
This.

Sounds like my truck pretty much exactly.

Cold weather it runs clean, produces little soot, passive regeneration happens easily, all regens at 24 hours.

Soon as the temps go up the truck runs filthy and can’t go more than 8-10 or so engine hours before it regenerates.

It has to be a tune / software issue where the truck isn’t adjusting to conditions adequately. The intake should be able to flow more than enough air. Yes cold air is denser but it’s hard for me to understand why the truck can’t adjust to be cleaner. I can’t imagine they want these trucks running that inefficiently. Could also be the amount of EGR being dosed in and when. The EGR dampens temps and makes passive regen harder to achieve due to the lower EGT’s.
 
This.

Sounds like my truck pretty much exactly.

Cold weather it runs clean, produces little soot, passive regeneration happens easily, all regens at 24 hours.

Soon as the temps go up the truck runs filthy and can’t go more than 8-10 or so engine hours before it regenerates.

It has to be a tune / software issue where the truck isn’t adjusting to conditions adequately. The intake should be able to flow more than enough air. Yes cold air is denser but it’s hard for me to understand why the truck can’t adjust to be cleaner. I can’t imagine they want these trucks running that inefficiently. Could also be the amount of EGR being dosed in and when. The EGR dampens temps and makes passive regen harder to achieve due to the lower EGT’s.
Mine will start getting in the EGT range to start passive regens and then the EGT’s will drop back to less than 600*. EGR percentage running 74-75% at times going down the road. I thought that was what DEF was for.

I think their EGR strategy is what is causing the problems. I also think that the delete devices that the EPA claimed Cummins had implemented on these trucks was the DEF/SCR system to be able to reduce the amount of EGR required to reduce NOX emissions.
 
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I am positive it’s tune related now. Did a hour and half interstate run in 70 degree wether and had soot load to first bar increment the whole trip with no passive regen. It is now 54 and from cold start and traffic (leaving Dollywood) then in 3 min of 50 mph it cleared off back to zero on the screen

Forgot to add I have a 22 with 115k on the clock, 3 1/2” lift, 35x12.5 tires.
 
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Mine will start getting in the EGT range to start passive regens and then the EGT’s will drop back to less than 600*. EGR percentage running 74-75% at times going down the road. I thought that was what DEF was for.

I think their EGR strategy is what is causing the problems. I also think that the delete devices that the EPA claimed Cummins had implemented on these trucks was the DEF/SCR system to be able to reduce the amount of EGR required to reduce NOX emissions.

I’m not sure it’s EGR related, my 22 uses so much less EGR than my 18 did and the 22 goes into soot based regen sometimes where the 18 never did.

I may drive the truck empty today and see what the EGR shows. Towing yesterday the EGR was less than 10% every time I looked at it.
 
I towed from Orlando to middle TN area and everything stayed at 0 load. The round trip was 26 hours of run time. I never noticed the 24 hour regen come on. I had the SGIII for a couple months now. Very nice to see what's going on with that device. I returned from that trip one week ago. Saturday had to make a 3 hour round trip mostly going 75 to 80, not towing. Whole time the load just kept creeping higher. Was much cooler weather in FL too. I didn't use Archoil on the towing trip but have it in now. I do think it helps but, shouldn't need to use it to begin with. In my experience the only time it passive regen's is towing something. Unfortunately no hills to bomb up in FL hahah.
 
Don't buy a 22, they fail and the manufacturer does not stand behind them....I bought a new 22 in June of 23. 4 trips to the dealer, including a dpf recall, replacement of dpf sensor, dpf filter assembly, and fuel rail actuator - all same problem within a year and under 13k. Took back to original dealer who made me an ok deal on a new 24 rebel 2500 diesel. Stellantis/FCA, after the fact offered some unknown incentive that they would not honor as I purchased the new vehicle - taking a bath on the old POS - prior to them deciding that they would do something. if you have one and it is under warrant and you have the opportunity and time available, use lemon laws and sue the living crap outta them. I could not as I had purchased a vehicle. I hope this new truck does well as I really do like it, but either way, due to their lack of actual customer support, I will not buy another stellantis product...
 
Don't buy a 22, they fail and the manufacturer does not stand behind them....I bought a new 22 in June of 23. 4 trips to the dealer, including a dpf recall, replacement of dpf sensor, dpf filter assembly, and fuel rail actuator - all same problem within a year and under 13k. Took back to original dealer who made me an ok deal on a new 24 rebel 2500 diesel. Stellantis/FCA, after the fact offered some unknown incentive that they would not honor as I purchased the new vehicle - taking a bath on the old POS - prior to them deciding that they would do something. if you have one and it is under warrant and you have the opportunity and time available, use lemon laws and sue the living crap outta them. I could not as I had purchased a vehicle. I hope this new truck does well as I really do like it, but either way, due to their lack of actual customer support, I will not buy another stellantis product...
I honestly doubt anything improved from 22 to 24. If it's a tune problem as many suspect then a code patch or update would solve the problem assuming the code was fixed for newer model years. If it is a defective component within these trucks then I'd think things like this thread or even just talking with technicians would show a common theme as to what exactly the problem component is. However, it seems to be throwing parts at the truck to make it go away (for now) is their answer while simply hoping we all age out of warranty. Unless or until something notable changes, I am not convinced any new model years will be different
 
Have to keep in mind that there a multitude of different components and systems that are tied together when it comes to DPF regeneration. A failure in any one of these systems is enough to cause issues, and it isn’t always easy to diagnose / find them. There can also be instances where there are issues with more than one aspect of this system and that makes it even more difficult. I don’t think there will be a one-size-fits-all solution to this problem. That being said, tuning and software are at the root of how it operates and that aspect definitely needs to be reviewed closer.
 
Have to keep in mind that there a multitude of different components and systems that are tied together when it comes to DPF regeneration. A failure in any one of these systems is enough to cause issues, and it isn’t always easy to diagnose / find them. There can also be instances where there are issues with more than one aspect of this system and that makes it even more difficult. I don’t think there will be a one-size-fits-all solution to this problem. That being said, tuning and software are at the root of how it operates and that aspect definitely needs to be reviewed closer.
I think your right and I think Ram is researching a resolution to the problem! Once the determination is made, correcting it where all the hardware/software seamlessly functions together I believe is very time consuming. After the CP4 pump failure resulted in the Y78 recall to the new CP3.3 pump, several 2019's experienced problems after pumps and software programming updates were preformed. The issue turned out that 2019's that had the VB6 emissions and several other software recall updates prior to the pump replacement, those software updates and the new CP3.3 software update didn't play nice together. So for those who's 19's had those recall updates, they were put on hold for another 8-12 months while new software was being developed to resolve the problem. I was one of those folks who had to wait, luckily I never had an issue with the CP4 while waiting!

I think Ram should be mailing out notices to affected owners addressing the problem(s), possible concerns that owners might be experiencing (fuel dilution etc.), and that steps are underway to discover and resolve the problem! It'll still be irritating waiting, but at least one would have acknowledgment of the problem and a resolution is in the works, and with an estimated date of a fix!
 
My 22 worked flawlessly up until about 27k miles. My dpg gauge never got barely over the 1/4 mark and only did the std 24hr regen. Now it’s been doing regens way too frequently. Here are my last 3 regens, it’s been doing this longer but I just started taking pictures and logging.

10-7-24 / 30,251 miles / idle 82 / drive 562
10-11-24 / 30,481 miles / idle 82 / drive 566
10-15-24 / 30,840 miles / idle 83 / drive 572

So you can see it made it a whopping 230 miles and 4 engine hours between regens. Then the Regen on 10-11-24 was right after we left the house with the camper last Friday. Of the 359 miles between the next Regen 321 of those was pulling our 7,500lb camper. The dpf gauge was at 0 when we got back on Sunday. By the time I made my 38 mile drive to work yesterday the dpf gauge was just under half full.
 
My 22 worked flawlessly up until about 27k miles. My dpg gauge never got barely over the 1/4 mark and only did the std 24hr regen. Now it’s been doing regens way too frequently. Here are my last 3 regens, it’s been doing this longer but I just started taking pictures and logging.

10-7-24 / 30,251 miles / idle 82 / drive 562
10-11-24 / 30,481 miles / idle 82 / drive 566
10-15-24 / 30,840 miles / idle 83 / drive 572

So you can see it made it a whopping 230 miles and 4 engine hours between regens. Then the Regen on 10-11-24 was right after we left the house with the camper last Friday. Of the 359 miles between the next Regen 321 of those was pulling our 7,500lb camper. The dpf gauge was at 0 when we got back on Sunday. By the time I made my 38 mile drive to work yesterday the dpf gauge was just under half full.
Does your truck fall under the build dates listed for TSB 25-005-24 for DPF regen frequency?
 
Does your truck fall under the build dates listed for TSB 25-005-24 for DPF regen frequency?
Speaking of the TSB, I hope they broaden the build dates and loosen the parameters for replacement. Even if experiencing problems, you have to have a check engine light set and in limp mode because of it or the threat of power reduction (can’t remember which off the top of my head) before they will even apply it.

I’m also not 100% sure that will even fix things since there are members that have had a new DPF just for the issues to return.
 
Does your truck fall under the build dates listed for TSB 25-005-24 for DPF regen frequency?
I haven’t checked but I will. But for now I have had no CEL’s come on. I spoke with the dealer this morning and I’m going to bring it in after we get back from a trip this weekend. He said they can scan it to see if there are any codes stored. If not there is nothing they can do. If that ends up being the case I’m just going to put my truck on a diet. I intended to do this if and when something happened I just didn’t expect it this soon. But that would still be cheaper than taking a loss and getting into something else.
 
My second truck is have thats having regen issues. Just replace air filter to weed out that idea. Running full does of archoil, temp this moring is 60degs and it just rained last night.

This moring towing through town 7k pounds it slowly climbed soot and before I got to freeway (about 10miles) it was at 1/4 soot. Hitting the freeway going over the pass it took 30miles for soot to drop to 1/4 and once I got to a slower part it climbed right back up to 3/8. I will probably hit regen when I leave the job site.
 
Very interested to see where this goes. I purchased a 2023 with 1000 miles on it just over a year ago. I had zero issues with the truck until it hit about 10,700 miles. One day I received the regen continue driving message, a few seconds later I received the power limited take to dealer message. I called the dealer and they were booked for the next three weeks so I forced the regen myself (Launch Scan Tool). One week later I received the take to dealer message again and parked the truck until my appointment date. Dealer performed a forced regen, updated the shift programing, and sent me on my way. Two days later the truck went into passive regen and took forever to complete. Over the course of the next 1000 miles (3 months) I would receive the passive regen notice every time I started the truck. One day the CEL came on and I had the excessive regen code so back to the dealer I went (last week). They had a recall for excessive regen which was a simple program update and they replaced my DPF filter. Two miles down the road and my friend passive regen came back on. I work on Mack and Freightliner snow plows almost everyday and and don't have this many issues. Just my two cents, we need to toughen up emissions in other countries and back off on ours just a little bit. Diesels used to be bulletproof now they are just an expensive boat anchor.
 
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