DPF gauge and filter gone crazy

[BighornHDRam]

Since my 2022 3500 SO truck with 6627 miles threw up the Exhaust Filter Full Power Reduced See Dealer CEL Back in July I have been having nothing but constant regen since. In 7486 miles I have logged 37 regens in those miles.

On 1-24-2023 my truck finished a regen with 17111 miles on it and within 80 miles the gauge is back to 34% by Saturday 1-28-2023. I don’t drive my truck Sunday but today I go to drive to the gym and it’s 21° outside and the drive in about 3 miles into the drive the DPF gauge goes from 34% down to 23% then another mile or so down to 12%. How is it possible to drop so much going only 55mph in such a short distance. I end up going to a few more places today and my mileage is at 17256 and the DPG gauge is back to 34%.

I’m at a loss with this DPF, one day it just climbs and climbs and then regens in 80 miles since last regen and then today it just baffles me. I have yet to see the programmed 24 hour regen that everyone talks about.

 

[elephantrider]

short trips, cold temps, will probably cause more active regens.

 

[BighornHDRam]

When I install my S&B 52 Gal tank and my Fleece fuel pump in a couple weeks I'm going to pull the SCR off and have a look at the back of the DPF and see if there is any damage from when I got the Exhaust Filter Full Power Reduced See Dealer CEL Back in July. If there is I will be sure to get some pics and to show them to the dealer to get it replaced. If it's all good then I guess it's just how this truck is going to run but I shouldn't of gotten that CEL at those low miles. BTW my truck has had the CCV filter changed twice already including the valve cover as well under warranty.

 

[BighornHDRam]

After a 7 month struggle with the ongoing constant regens happening on my truck I finally got the dealer to look into it. After digging into my 2022 3500 with 17500 miles on it they found that it had a Injector Timing DTC and suspected the DPF was face plugged. They then proceeded to order a new DPF and 6 new injectors for my truck.

Upon removal of the injectors they found that some of the fuel injector connector nuts where loose that hold in the connector feed tube and removing the original injectors one of the M6 bolts was stretched and one broke off upon removal but managed to remove it without drilling it out, My truck is still in the shop waiting on the new M6 bolts.

In one of the pics I’m curious as to why they removed the EGR air horn going into the grid heater, Maybe while they were in there to inspect the grid heater recall that maybe coming? I have provided a pic of the inlet to the DPF but forgot to get a pic of the outlet, the outlet looked clean compared to the inlet thou. They also told me they are having issues with the Ram air filter with the glue on them on the 2022 trucks as well.

 

[flan]

Feed tubes are one time use, they probably had to take the intake horn off to get the feed tubes out for the first couple cylinders.

 

[AH64ID]

Feed tubes are one time use, they probably had to take the intake horn off to get the feed tubes out for the first couple cylinders.

Is that new that feed tubes are one time use?

But I do agree that they horn was removed to pull the tubes.

 

[flan]

Is that new that feed tubes are one time use?

But I do agree that they horn was removed to pull the tubes.

They are crush fit and mold to the injector. That being said I’m sure they get reused all the time but there’s the risk of hard start and external leakage. A pinpoint 26k psi leak may be enough to cause a bigger leak over time by erosion too?

 

[H3LZSN1P3R]

Is that new that feed tubes are one time use?

But I do agree that they horn was removed to pull the tubes.

Its always been that way but not many people want to spend the 600$ CAD to change the feed tubes so they usually get reasembled issue free.

 

[AH64ID]

They are crush fit and mold to the injector. That being said I’m sure they get reused all the time but there’s the risk of hard start and external leakage. A pinpoint 26k psi leak may be enough to cause a bigger leak over time by erosion too?

Its always been that way but not many people want to spend the 600$ CAD to change the feed tubes so they usually get reasembled issue free.

I haven’t bought a FSM for my ‘22 yet, and never did for the ‘18, but they were not one time use on my ‘05. I also have a ‘08 FSM and it’s the same.

The FSM does call for several new components during the injector install, but the crossover tube is not one. They list inspection criteria for reuse.

It also mentions that overtorquing the tube will deform the tube and the injector, which means they are not crush molded into the injector on a proper install but rather they are seated into the injector.

They are often replaced on higher mileage rigs, or after a couple times on installation/removal, but unless there has been a change they don’t have to be replaced every time.

 

[flan]

They harp on that 37ft/lb pretty hard, seems the critical number for problem free install.

 

[elephantrider]

great info and very interesting.

 

[H3LZSN1P3R]

I haven’t bought a FSM for my ‘22 yet, and never did for the ‘18, but they were not one time use on my ‘05. I also have a ‘08 FSM and it’s the same.

The FSM does call for several new components during the injector install, but the crossover tube is not one. They list inspection criteria for reuse.

It also mentions that overtorquing the tube will deform the tube and the injector, which means they are not crush molded into the injector on a proper install but rather they are seated into the injector.

They are often replaced on higher mileage rigs, or after a couple times on installation/removal, but unless there has been a change they don’t have to be replaced every time.

The only time i have changed lines is when they crack its usually #6 that does it

 

[flan]

The only time i have changed lines is when they crack its usually #6 that does it

#4 was famous for cracking on the early CR’s, I kept a spare in my glovebox!

 

[H3LZSN1P3R]

#4 was famous for cracking on the early CR’s, I kept a spare in my glovebox!

I have never seen #4 crack before but it would have been better than #6 i usually take 4-5 off to change 6 so would be a couple less steps

 

[AH64ID]

#4 was famous for cracking on the early CR’s, I kept a spare in my glovebox!

I carried a spare as well.

I've never heard of a #6 cracking, is that a 6.7 thing?

 

[H3LZSN1P3R]

I carried a spare as well.

I've never heard of a #6 cracking, is that a 6.7 thing?

That was 04.5-07 that i found i had to change #6 often enough

 

[AH64ID]

That was 04.5-07 that i found i had to change #6 often enough

Interesting, first I’ve heard of #6 and I’ve been pretty involved in these trucks since I bought my 05 in 07.

 

[H3LZSN1P3R]

Interesting, first I’ve heard of #6 and I’ve been pretty involved in these trucks since I bought my 05 in 07.

I don’t think it’s a big widespread issue. Mind you my 05 I had 350,000 on it never touched it It just seemed that was the only line I have ever had to change on those trucks as a mechanic. that and the return line coming off the back of the head.

 

[BighornHDRam]

Got my truck back 2-21-23 after all 6 injectors and feed tubes and DPF where replaced, upon leaving the dealer the DPF filter went to 13% after 25 miles then at 60 miles to 24%. The next day it did a active regen and went back down to 13%. Today on the way to get the S&B 52 gallon tank and Fleece Flo-Pro fuel pump installed today it does another active regen back to 0%. The code my truck had stored was P020A.

At the moment I'm going to call this a win for now, only thing is the outside of my truck smells of Diesel fuel as one of the feed lines from the rail to feed tubes had a leak and needed to be replaced as well after they got it all put back together.