Take heart, you are not alone in your frustration, anger and hostility toward Chrysler/Dodge over the nightmare of the Dodge Ram 2500 and 3500 DPF problems. Everything from lousy fuel economy to constant check engine and DPF lights, stalling and “limp” mode behavior on trucks costing $50k is true. Read on my friends, and I’ll keep you posted on Class-action lawsuits, and DPF delete modules; DPF removal .
“A) Your 6.7 has two problems:
1. EGR – Exhaust Gas Return – your exhaust system recycles spent fuel back into the engine and uses a butterfly valve to close off clean air from coming in. Diesel never will burn clean. It contains sulfur… even the ULSD. It will ALWAYS produce soot. Recycling soot back into your engine is bad.
2. DPF – Diesel Particulate Filter – your emissions system contains a DPF that has a coated screen in it. This screen collects the soot. Using sensors, your computer detects when the DPF is full (by air pressure behind the DPF) and sends your truck into REGEN mode. This causes your engine to burn massive amounts of fuel to essentially atomize the soot into carbon monoxide. Unfortunately, this doesn’t happen 100% and eventually your DPF fully clogs. Guess what’s next in line??? The soot backs up your exhaust system, up the down-pipe into the turbo. The soot then clogs the turbo veins causing sticking either in the open or closed position. This will soon destroy the turbo. After this, the soot clogs even further back up into your EGR system, damaging the EGR valve and the engine. The DPF essentially strangles your engine to death slowly.
B)The fixes:
1. Chrysler/Dodge/Cummins does not have a fix. They haven’t released an 09 2500/3500 truck yet because of this issue. More importantly, they’re hoping through cleanings and turbo replacements to get you through your 100k powertrain warranty so they can wash their hands of the problem. So right now, calculate the cost of a new turbo… $2400. A new DPF… about the same. And how much do you think a technician cleaning your DPF and exhaust will cost??? The question is, how can you prolong the life of your truck and not have to worry about mile 100001…
2. EGR blockoff kit – this blocks the valve and a tube redirects the coolant back into the coolant system. The block-off creates a high pressure area in your exhaust preventing the exhaust from entering the EGR pipe and cooler, and allows it to fully be expelled from the truck. Your computer will produce soft codes and possibly send you into “limp” mode… I haven’t tested this yet… doing that tomorrow. But this will prevent soot from being sent back through the engine.
3. DPF delete kit – a straight pipe with muffler running “turbo back”. Sensor and pressure fooler boxes hook into the existing wiring harness and you reuse the O2 sensors. Your engine will throw soft codes (a ‘P’ code about low pressure) but not enter limp mode. I’ve done this. This allows your truck to breath again and expel soot so it doesn’t clog again.
4. An Edge tuner or similar tuning device to clear soft codes on startup automatically so you don’t hear the annoying ding coming from the computer every 10 minutes.
C)What’s this mean:
1. Mileage, durability and lifespan of your engine will drastically improve. You will essentially have the old 5.9L back, with the displacement of 6.7.
2. You’ve just violated EPA regulations, and you may get an improper equipment ticket. Whoopie. Oh, you also won’t pass state inspection where emissions are checked. Central Virginia… check! 
3. YOU HAVE NOT VOIDED YOUR WARRANTY. Under consumer protection laws, the dealership MUST prove that the modification you did caused the damage if you go in for a warranty claim. Since the two things you’ve done actually improved the engine, they’ll never be able to prove that… but you’ll probably have to have a knock-down drag-out fight with them… but usually once you say lawyer, or throw a fit in front of several potential car sales, they won’t put up a fight. They can void your emissions system warranty, because you’ve completely removed it via the DPF delete kit. So yes, if your 6.7 has a horrible problem and throws a rod or explodes, they will be replacing that $15k monster via your warranty because there’s no way an EGR or DPF would cause that.
So, overall, and my personal thoughts… some lobbyist in Washington put pressure on congress and the EPA to release these standards without fully understanding the principles of diesel fuel and was just tired of seeing soot rolling out of exhaust pipes. Bottom line, the emissions controls worsened the vehicles to the point where they burn 30% more fuel to create just as much pollution and go the same distance, plus they slow kill themselves. How do you explain that??? You want to enforce a new emissions system that burns 30% more of a precious resource that will eventually run out.
NOTE: regardless of the mods to your 6.7L, remember to always use ULSD and ashless CJ-4 rated oil – the 6.7 was designed for no less.”
So there you have it… Thanks David.
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Sarah Lee is a 20 yr. automotive executive writing on all things car related. A huge consumer advocate for better car deals and manufacturer responsibility. This website and the information provided is fueled by donations. If you feel the information provided is helpful, please feel free to contribute by clicking here. Thank You for your support. SLM
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Can’t agree more with the said above.
Comment by Yavor — 12/23/2008 @ 5:13 am
how many amps does my 07 dodge ram 3500 6.7 diesel pull..the altenator is a stock 136amp.. is it possible to put am amplifire on it that pulls 30 amps..i also have some offroad lights on it..
Comment by Bill — 12/28/2008 @ 4:38 am
good post and keep up the good work. Common sense could go along way in this country if people would just use some.
Thanks
Comment by rob wolfley — 06/06/2009 @ 10:59 pm
Website
im 52 years old and have been reading every thing on diesel trucks and bought my first new 2008 dodge ram truck and even though i have only 8000 miles on truck and i still think it is a unbeleivable truck and love to drive it i realize that the dealers promise of 21-24 miles per a gallon was a lie and the whole dpf system makes my spending over 60,000 is the bigest mistake i have ever made, i worked for mta transit in la for 23 years and they removed the particulate traps years ago because of engine failure and i under stand most truckers have some type of overide systems to get it going again when it clogs, i cant beleive i didnt hear one word about dpf from the saleman or in magizines but every were you look on any book ,magazine or website tells what a lemon i now own and am stuck with, i started to look up cummins because my truck has had the engine light on most of the time that i have owned it and intell they said recently replaced both oxgen sensors and rapped the exhaust the truck always smelt like some thing burning, but even though it has been back to the dealer more than 25 or so times i now realized what a sham, none of the papers on invoices say any thing except about oil changes or non important things so i really have no proof and even though i told the dealers nothing that shows a problem to leave a paper trail is left, i wish there was something i could do or someware i could sign to get action for the crime that has happened, but even though this is my first and last new vehicle i will ever own nobody twisted my hand or put a gun to my head to sign and buy and all the reveiws for deisels were so fantastic that i beg borrowed and ? whatever to get this diamond ,but never did i realise that after i signed it on the line that i was mistaken it was just a lump of coal,i feel throughly sick threw and threw sincerly Ken Steinbaugh
Comment by ken — 08/25/2009 @ 12:03 am
i own a 2007 dodge 2500 with the 6.7,i have only been to the dealer once for an exhaust clean out.i bought the truck about a year ago now with 14089 miles on it and no mods to the engine.the CEL came on at about 19000,i took it to the dealer and they said it needed cleaned.(which is under warrenty)i picked it up the next day and everything was fine.they said these engines are made to run.i understand this completly.(i admit that i have babied my truck but who wouldnt after spending $35000)sense then about a month ago the CEL came on but this time insted of going to the dealer i took my truck to I 70 and opened it up on the on ramp and got the motor hot on east bound I 70 for 2 miles and got off and came back I 70 west and did the same thing,went home and let the truck cool down in the drive way with the engine running(like you should for all turbo engines)for 5 min.then shut it off and waited an hour and started it up and no CEL.this just goes to show diesels are made to work and generate heat.these other diesel owners who are complainig about DPF build up just bought there truck to show off and keep up with the jones.if you dont like sell it, but the NEW DODGE 6.7 IS UNBEATABLE FOR POWER AND ECONOMY(AND ITS ONLY A INLINE 6 CYLENDER)
STOCK 350 HP,610 ft/lbs TQ—-CITY MPG 17.3/HIGHWAY 23.4
AEM DRYFLOW INTAKE ONLY,NO CHIPS,NO DELETES
Comment by JOSH (MARYLAND) — 09/18/2009 @ 3:27 pm
What kinda fine can they give you for deleting the dpf and egr
Comment by Bryan — 11/16/2009 @ 8:00 pm
YOU IGNORANT DEMOCRAT COOL AID DRINKING GLOBAL WARMING FANATICS ARE ABOUT THE STUPIDEST PEOPLE I KNOW. WHILE I LOVE MOST OF THE FEATURES OF MY TRUCKS THEY ARE NOT NEAR THE TRUCK THE 5.9S WERE. AND THEY DO TAKE 30% MORE FUEL THAN THEY SHOULD. ONE THING FOR SURE WE WILL RUN OUT OF OIL SOME DAY BUT THIS GLOBAL WARMING BULL SHIT MYTH IS A FARCE DREAMED UP BY AL GORE AND OTHER DUMB ASSES. TRUTH IS THE EARTH GOES THROUGH WARMING AND COOLING CYCLES NATURALLY DOESN’T HAVE ANYTHING TO DO WITH GREEN HOUSE GAS EMISSIONS AND UNTIL WE GET OFF OUR ASSES AND THROW THESE IDIOT POLITICIANS OUT OF OFFICE AND PUT SOME REAL CONSERVATIVE PEOPLE IN THERE THAT HAVE A BACKBONE TO STAND UP TO THESE IDIOTS WE’RE GOING TO HAVE TO KEEP PUTTING UP WITH BULL SHIT LIKE THE IGNORANUS PARTICULATE SYSTEM!!!!!!!!!!!!!!
Comment by john — 12/08/2009 @ 8:26 pm
Brian, you will fail emision tests terrible and you will still have dash and over head warnings. Threaten a Lemon lawsuit and your dealer will sweet talk like a kitten.Better yet get a magnetic sticker that says, “I bought this Lemon from so and so Dodge”. I am waiting for a call back from my Lemon law attorney. I have had my turbo replaced twice, untold egr sensors, map sensors, heat sensors, replace this replace that. If all the above fail I will print a sign and parade the sidewalks of this stupid dealer, it is ok under freedom of speech; telling every passing vehicle what a Lemon this dealer sold me! They will beg for me to go away. I will get what I demand.
Comment by Daryl — 02/09/2010 @ 8:30 pm
I have a 2007 3500 DRW with a 6.7 I bought the truck used with 24K miles and have enjoyed the trucks drive and ride.
I have had problems with air into the cooling system. I have the EGR Delete and 5″ Turbo Back Exhaust. The truck runs a lot better and mileage is averaging 18.3 over the past 2 months. But the air in the coolant is so bad when the truckis loaded it pushes coolant out the resevior. I carried the truck to Elders Dodge for repairs and was told it would not be covered by warranty by Dodge but they would replace the head gasket and stand behind there work. They replaced (?) the head gasket and I upgraded to ARP head bolts. Problem should be fixed right? After two weeks I pulled another load and had the same problem!!! After consulting with many mechanics I have one of two problems another blown head gasket or a cracked head. After the mechanic removed the head and inspected there was no sign that the head had been off to replace the gasket. This was confermed by another mechanic, I was told that it looked like I got a new set of ARP studs and retorked the head whiched stopped the exhaust in coolant problem until it was put under a load. The head is being checked now. By the way Elders Dodge in Athens TX did NOT stand behind there work!!! The truck is at another repair shop that let me see everything after they removed the head. I hate dealerships!
Comment by Tony — 03/17/2010 @ 9:15 pm
I just bought an 09 3500 4×4 it has 40k on it I hear all this about this regen and I have had mine fir about 2 weeks it has never said anything about a regen on the monitor. I want to put straights on it but lookin for advice I just got rid of my power choke andlookin for info thanks bro
Comment by Daniel — 08/24/2011 @ 4:49 pm
I have had a 2009 3500 4X4 since it was new (test drove it@ 6miles) and at 45K, am about to have it in for DPF replacement for the second time. It has NEVER said anything about regen – it chokes down the engine and tells me the DPF is 80% full and running on reduced power….see my dealer!
It seems strange to me that BOTH times this has happened are when I need the FULL POWER the most – hauling in the hill country….but, OH NO….
Otherwise, I LOVE MY TRUCK! She’s a BEAST!!!
Comment by Teresa — 09/06/2011 @ 9:28 am
After reading your article I realized how little you know about the operation of a 6.7. If you going to bash it get your info correct. I’ve worked on many of these and the people that actually work them have very few problems. And I don’t mean getting groceries or your manicure.
Comment by mike — 09/06/2011 @ 6:41 pm
Read the diesel supplement…if you don’t want the problems take it out for a run at highway speeds for 20-30 min., it will burn the stuff off…if you do, then you may not be doing it enough. I have a ’09 6.7 (2500), I live off an interstate and in a rural location so I have to drive to get things I need, I have yet to have any issues related, however the price of diesel is up, but I need the power and better fuel economy. It’s not a city driver vehicle, so take it out drive it to burn it off, you spent the money, enjoy it wisely.
The DPF is ridiculous, the EGR Cooler is a nice concept…but yes your fuel economy will suffer. Just check out the dozens of posts of going from 13 mpg to 18+ mpg just for the removal of the EGR system. The information is all over the web on various forums with various specifics.
There are are many manufacturers of the EGR Valve/Cooler Deletes Kits, various sim plug-ins, DPF Delete Kits pipes from turbo back or just the turbo to muffler. The big thing is if you do these you need an appropriate Tuner…in most cases a race tuner…once again a variety exist. Since these items are readily available just order from your closest retailer…saves on shipping time…since in most cases all items are priced the same. If you do any changes to the exhaust it is also recommended that you get a better flowing cold air intake to replace stock. Anyway…you do this you will gain hp/tq and improve fuel economy. Options are endless…choose to your liking.
Hey I agree in keeping emissions to a minimum, and the smell of a true diesel isn’t the greatest, but if they are going to do it, then make them work for all conditions. For those that are doing as suggested in the Diesel Supplement…yes if you are still having problems…that is a problem, make them stand by their claims, also keep a seperate maintenance log…and keep all receipts, ask for one that notates actions taken. It will help if you ever end up in a legal battle.
Comment by justin — 11/14/2011 @ 11:03 am
Who care about a fine.. I would rather my truck last 4 times longer.. Fine me i will never have a DPF/cat/ or egr on any of my new diesels.. ANd i have a bunch of them.. I took of the egr/dpf/ and both cats off my 2011 cummins.. Truck now gets 3.6 miles better per gallon.. Motor will last longer and my oil stays cleaner.. Lab proven..
Comment by phil bob — 11/15/2011 @ 11:24 am
I think it’s retarded that in order to gain mileage and hp out of a truck that cost me $36,000, I have to spend another $2000 for a DPF delete and a tuner. Way to stand behind your product Dodge!
Comment by Bill — 12/19/2011 @ 3:03 pm