I am half way through this topic and have not read all the posts, but I would like to she what I experienced today.
I have the same problem with frequent regens. I changed oil, fuel filters, ccv filter and air filter. My air filter is incorrect one and I changed it when I received my truck from Texas in Alaska. The new filter is on order and should arrive in a few days or so.
Today, after reading some posts I cleaned up my map sensor with electric contact cleaner. When I put it back I got error messages for MAP sensor and air cooler temperature circuits. Then I removed the sensor again and cleaned it with crc maf cleaner.
I took the truck for a drive and got my dpf filter percentage jumped from 30 to 100 in a minute or so. By the time I arrived to my destination (5-7 miles) the percentage dropped to 80. When I arrived I checked the error code again and it was gone.
I drove back home and my dpf is still at regen and at 40% now.
I own a 2021 Ram 2500 6.7L Tradesman with over 77,xxx miles. We have tens of thousands of miles towing our RV around.
2 years ago, when doing oil and filters change, I installed a cheap air filter. And right off, while towing too, I started to have soot build up and excess regens, even while towing. Towing always kept the DPF cleared out. And while going up over the continental divide in Wyoming into Jackson Hole, I had the "DPF 100% full, Power reduced, See Dealer" message. Once over the top, luckily for me, my EGT,s were enough to clear out the DPF, and after a bit the Regen restarted and after 60 miles, cleared out the DPF. When I passed the next NAPA, I bought a NAPA air filter, and those issues went away, mostly.
And I think this started a slow but down hill problem of too many regens, but it wasn't an issue until last summer. I think too many short drives, maybe, not sure, but I had another 100 % Full message. With AlfaOBD and a phone, plus the bypass cable, I was able to initiate a stationary regen. Good thing, where we were was 100 miles away from a Ram dealer. But the Regen issues slowly got worse, towing no longer kept the DPF cleared out.
I kept track of regens this last few months, and many cycles were under 100 miles, but not always. I had one interval of 320 miles, this was desert driving, it was 60 miles to town, and in the past that was enough to clear out the DPF. Last April, right after a fresh regen, I drove to a market about 15 miles away. And in 12 miles, my DPF filled up and started another regen. My oil was showing signs of dilution too, aka, the dip stick level was rising. This time I took it to a Ram dealer. They conceded that there was an issue. AFter a month, the replaced the MAF and NOX sensor, and claimed it was fixed. NOT.
The next day we hitched up to our 5th wheel and headed north. And I was still having issues with the DPF filling up. One morning on our trip, I only got 8 miles until the next regen. So, I took the truck to the Ram dealer in Sand Point, Idaho. This time I told the dealer to his face to borescope the DPF, they did, and told me it was face plugged and needed replacement. So $2500 later, I pick up my truck and damnation, in 180 miles, I'm doing another regen.
Man I was effing pissed. HOT as the sun!! So I did a hail mary and did the MAF relearn procedure, I got this on this thread. I got on a flat road, and at 64 MPH in 4th gear kept my RPM,s at 2600 or so with Cruise control, followed the procedure to the T. About 15 miles per leg. Find a road with no hills and no stops.
And just like that, it seems to be fixed. So far, I have over 625 miles since my last regen. The DPF is up around 85% full, but this seems perfectly normal now. All through this issue, my truck always ran great, mileage was and still is wonderful.
Anyone who has used the wrong air filter, and has regen issues, should try this procedure first after installing the correct air filter. I went too long with this issue, and it finally caught up to me, and corked the DPF.
