2022 Ram 3500 HO 6.7L Cummins Diesel Particulate Filter error

[RaySchmidt]

Wanted to see if anyone else is currently having or has had this issue in the past. My 3500 is maybe a few months old, however during one of my longer drives the check engine light came on. After reading it with a scanner and checking the info provided on the dash (such as temps, as well as where it tells you the DPF is regenerating) it came back saying there is something wrong with the DPF, and after talking to my dealership, I was told to bring the truck in asap for them to diagnose it and try and fix it. The first dealership I went to ended up charging me an insane amount of money to fix the issue, after holding onto the vehicle for longer than needed, however the problem was supposedly fixed. Not even a week later the check engine light came on again and it was the same exact problem. I brought it to a different dealership and after explaining the issue and what the first dealership did, was told they should not have charged me and that it was all covered by warranty (which is a problem on its own but not one Ill bring up now). The issue was once again supposedly fixed and I went about my business. However the light is now back AGAIN for the third time, and the scanner is giving me the exact same error code. Im bringing the truck in for the third time again to have it looked at, but I wanted to see if anyone else is experiencing or has experienced an issue like this or something similar, and how you went about correcting the issue. This has all happened in the timespan of around 2 weeks. I dont want this to become a normal occurrence, and I don't want to continue to have issues with the DPF or any issues with possibly breaking down. Thanks in advance for any help/response!

 

[flan]

What do you have for miles on the truck? Emissions is good for around 50k+ miles depending what state you live in. What have they done to it so far according to your work order?

 

[2Many12Valves]

Any luck figuring it out? My check engine light just came on I have 59,000 miles on 21 Ho 3500, particulate filter code.

 

[ZMcCoy]

54K on my truck. Same issue, local dealer simply cleared the code, said they'd never seen it before. Happened around 45K. Came on again, but went away before I could get it to the dealer. Now it's back on, going in on Monday. Noticed a small puddle of oil under the front of the engine this morning, so they'll be looking at that as well. If I'm lucky they'll only have it for a week or so.

 

[mbarber84]

There are a list of things they need to check in the proper sequence in order to determine what’s going on. Please post pictures of the work orders they completed so that we can see what they’ve done thus far, as well as what DTC’s have been triggering in your ECM, your mileage on the truck currently and your engine hours (idle, drive, total)

There have been a ton of “DPF full” and “DPF regeneration frequency” issues with the 2022’s.

The simplest place to start is the engine air filter. Are you running a completely stock truck, and if so, which air filter are you running? (Brand and part number). If you’re not running a Mopar 53034051AB or a Fleetguard AF27684, that is the first thing to change.

If the air filter is as listed above, then there are some diagnostics that need to be checked out. My guess would be a faulty DPF differential pressure sensor, but without more info on the truck I don’t want to speculate as this is one of those problems that has a number of different causes. If the dealer you’re working with doesn’t have an experienced diesel technician on staff, you’re going to want to find another one that does. Too many parts exchangers these days and it takes more understanding than just being able to read a factory-prescribed diagnostic procedure to be efficient and effective at diagnosing these issues.

 

[js4024]

There are a list of things they need to check in the proper sequence in order to determine what’s going on. Please post pictures of the work orders they completed so that we can see what they’ve done thus far, as well as what DTC’s have been triggering in your ECM, your mileage on the truck currently and your engine hours (idle, drive, total)

There have been a ton of “DPF full” and “DPF regeneration frequency” issues with the 2022’s.

The simplest place to start is the engine air filter. Are you running a completely stock truck, and if so, which air filter are you running? (Brand and part number). If you’re not running a Mopar 53034051AB or a Fleetguard AF27684, that is the first thing to change.

If the air filter is as listed above, then there are some diagnostics that need to be checked out. My guess would be a faulty DPF differential pressure sensor, but without more info on the truck I don’t want to speculate as this is one of those problems that has a number of different causes. If the dealer you’re working with doesn’t have an experienced diesel technician on staff, you’re going to want to find another one that does. Too many parts exchangers these days and it takes more understanding than just being able to read a factory-prescribed diagnostic procedure to be efficient and effective at diagnosing these issues.

I am seeing this late, but my 2022 HO 6.7 seems to regen every 20 miles or so. Had it to the dealer and they said... you have too much oil in the crankcase.....
I said how much should I have? they said 12 quartz, but... you have to let it drip for AT LEAST a half hour. So after a full oil change, let it drip for an HOUR, still regen every 20 miles. I think the engine hides a quart or more of dirty oil somewhere. If I fill it to the full mark on the dipstick the next day I am over full. Mechanic said, it contaminates your EGR filter. So I said, the manual says 12 quarts of oil, I put in enough to hit the top full mark, then the next day its over filled??? He said that is why the DPF is regenerating every 20 - 30 miles.. And then he said, these trucks were not meant to be daily drivers..... WTF???

 

[56ram2500]

I am seeing this late, but my 2022 HO 6.7 seems to regen every 20 miles or so. Had it to the dealer and they said... you have too much oil in the crankcase.....
I said how much should I have? they said 12 quartz, but... you have to let it drip for AT LEAST a half hour. So after a full oil change, let it drip for an HOUR, still regen every 20 miles. I think the engine hides a quart or more of dirty oil somewhere. If I fill it to the full mark on the dipstick the next day I am over full. Mechanic said, it contaminates your EGR filter. So I said, the manual says 12 quarts of oil, I put in enough to hit the top full mark, then the next day its over filled??? He said that is why the DPF is regenerating every 20 - 30 miles.. And then he said, these trucks were not meant to be daily drivers..... WTF???

Letting hot oil drain a full 30 minutes after shut off is all that is needed, the engine is not hiding a qt of oil any where, but if it make you feel good drain it for a full hour if ya got the time then refill with 3 gallons of oil an new oil filter, some of your oil growth could be frequent regens but you also may bad injectors.... As for daily driver the engine need to see the hwy at least once a week for a good 40+ minutes non stop to help with passive regens. In my truck I never had 20-30 mile regens like you mine were every 300 miles or so, now that I use Archoil 6400D followed by 1-2 oz Archoil 6500 per 10 gallons in every tank I can now go a full 24 hour, over 700 miles between regens... Good Luck

 

[mbarber84]

I am seeing this late, but my 2022 HO 6.7 seems to regen every 20 miles or so. Had it to the dealer and they said... you have too much oil in the crankcase.....
I said how much should I have? they said 12 quartz, but... you have to let it drip for AT LEAST a half hour. So after a full oil change, let it drip for an HOUR, still regen every 20 miles. I think the engine hides a quart or more of dirty oil somewhere. If I fill it to the full mark on the dipstick the next day I am over full. Mechanic said, it contaminates your EGR filter. So I said, the manual says 12 quarts of oil, I put in enough to hit the top full mark, then the next day its over filled??? He said that is why the DPF is regenerating every 20 - 30 miles.. And then he said, these trucks were not meant to be daily drivers..... WTF???

1. An overfilled crankcase can definitely lead to more frequent regeneration.

2. Draining the oil when hot for an hour is more than sufficient. There’s very little residual oil in there after that length of drain time.

3. It’s a simple refill. 12 quarts including the filter.

4. Now that the truck has been operated with an overfilled crankcase, I would recommend changing out the CCV filter, as well as pulling the intake boot off the charger side of turbo and check for excessive oil in the turbo inlet.

5. What brand / part number engine air filter are you using?

6. What are your engien idle and drive hours?

7. What does your trucks daily duty cycle look like?

8. Does your truck fall within the build date range listed on TSB 25-005-24?

9. Are you getting a check engine light, with code P2459 showing active?

10. Has the dealership replaced anything or cleared anything for you?

 

[js4024]

1. An overfilled crankcase can definitely lead to more frequent regeneration.

2. Draining the oil when hot for an hour is more than sufficient. There’s very little residual oil in there after that length of drain time.

3. It’s a simple refill. 12 quarts including the filter.

4. Now that the truck has been operated with an overfilled crankcase, I would recommend changing out the CCV filter, as well as pulling the intake boot off the charger side of turbo and check for excessive oil in the turbo inlet.

5. What brand / part number engine air filter are you using?

6. What are your engien idle and drive hours?

7. What does your trucks daily duty cycle look like?

8. Does your truck fall within the build date range listed on TSB 25-005-24?

9. Are you getting a check engine light, with code P2459 showing active?

10. Has the dealership replaced anything or cleared anything for you?

So we move further down the road. Had a WIX air filter, Dealer said its too restrictive... ie "too good"... They gave me some Chinese made filter and said try this. Worked fine for a few weeks then right back to every 20 miles having to regen. Mind you I have had the truck for 4 years! 3 full winters and never had an issue, no change in how I drive, it is 4 years old this October and it has 26,000 miles on it. I use it as a truck to haul dump trialers and tractors around. Since January this problem has intensified. The end of June they replaced the DPF filter and sensors. Replaced my MAS with one made in China, the one made in Germany was too good I guess. They pulled the outlet from the turbo to check for oil seals, nothing, clean as a whistle, the crank case filter was replaced way back in April. Supposedly Cummins says its good for 60k miles?? NOT, that think was packed full. Must have weighted atleast 5 lbs. So they did the entire check list, replace the DPF and now instead of every day doing a regen its every other day. I may get 150 miles before it does a regen. And all this started in January 2025 after 3.5 years of use and no change in how I drive it. I have to believe I have either a bad injector, or a bad set of piston rings on one of the pistons. I had my oil analyzed at 2100 miles right after they DPF replacement and it came back critical, fuel dilution is 6.9. Normal is less than 2. They have no clue... About to join the Ford forum...

 

[56ram2500]

So we move further down the road. Had a WIX air filter, Dealer said its too restrictive... ie "too good"... They gave me some Chinese made filter and said try this. Worked fine for a few weeks then right back to every 20 miles having to regen. Mind you I have had the truck for 4 years! 3 full winters and never had an issue, no change in how I drive, it is 4 years old this October and it has 26,000 miles on it. I use it as a truck to haul dump trialers and tractors around. Since January this problem has intensified. The end of June they replaced the DPF filter and sensors. Replaced my MAS with one made in China, the one made in Germany was too good I guess. They pulled the outlet from the turbo to check for oil seals, nothing, clean as a whistle, the crank case filter was replaced way back in April. Supposedly Cummins says its good for 60k miles?? NOT, that think was packed full. Must have weighted atleast 5 lbs. So they did the entire check list, replace the DPF and now instead of every day doing a regen its every other day. I may get 150 miles before it does a regen. And all this started in January 2025 after 3.5 years of use and no change in how I drive it. I have to believe I have either a bad injector, or a bad set of piston rings on one of the pistons. I had my oil analyzed at 2100 miles right after they DPF replacement and it came back critical, fuel dilution is 6.9. Normal is less than 2. They have no clue... About to join the Ford forum...

Sounds like either leaking injector(s) or the HPFP is leaking... As for air filters I use the Fleetguard AF27684 it has no glue strips....

 

[js4024]

Well I am in it deep again, don't bother with the RAM care people.. They are located in India. So after only 1300 miles my oil level increased! Regenerating every 150 miles like clock work. I carefully filled the oil level to 1/2 way up the "SAFE" zone on the last oil change... (Fuel dilution was 6.9 at 2100 miles, should be less than 2 so I changed the oil and filter.) Checked it cold and hot, now I am at the very top of the safe zone. I spoke to a different dealer... (Ram Care people suggested to take it to a different dealer.) I said I have to have a leaking injector, they said how are you so sure you have a leaking injector. How else am I getting such a high rate of fuel dilution with such short mileage? Something is sooting up the DPF... I said, just order me 6 new injectors and I will fix the GD issue myself. He said, well we can't just order parts.... If not the injectors, then I need a new engine as the oil control rings are shot. How many miles on the truck 26800 miles. I have had the truck for almost 4 years. change the oil/filter annually at about 7k miles and use Amsoil and this issue started in March of 2025. New DPF, new air filter, new crank case filter. I am thinking a blue oval truck is in my future. Screw this crap!

 

[56ram2500]

Well I am in it deep again, don't bother with the RAM care people.. They are located in India. So after only 1300 miles my oil level increased! Regenerating every 150 miles like clock work. I carefully filled the oil level to 1/2 way up the "SAFE" zone on the last oil change... (Fuel dilution was 6.9 at 2100 miles, should be less than 2 so I changed the oil and filter.) Checked it cold and hot, now I am at the very top of the safe zone. I spoke to a different dealer... (Ram Care people suggested to take it to a different dealer.) I said I have to have a leaking injector, they said how are you so sure you have a leaking injector. How else am I getting such a high rate of fuel dilution with such short mileage? Something is sooting up the DPF... I said, just order me 6 new injectors and I will fix the GD issue myself. He said, well we can't just order parts.... If not the injectors, then I need a new engine as the oil control rings are shot. How many miles on the truck 26800 miles. I have had the truck for almost 4 years. change the oil/filter annually at about 7k miles and use Amsoil and this issue started in March of 2025. New DPF, new air filter, new crank case filter. I am thinking a blue oval truck is in my future. Screw this crap!

Its still under power train warranty they should get the okay to check the HPFP and if its teste okay then get the oaky to pull injectors and have them sent out to have them bench flow tested at a Bosch authorized service center......

 

[Resilient]

Fuel getting into crankcase during the regen cycle. Raw diesel getting past the piston rings. The more frequent the regen cycling, the more raw diesel in the cylinders and leaking into the crankcase. More diesel in oil means less ability for the oil to lubricate and seal. This has to rapidly increase engine wear.