Diesel Particulate Filter

This procedure covers the removal and replacement of the Diesel Particulate Filter (DPF) on 2007+ Dodge Ram 2500 trucks equipped with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Diesel Particulate Filter assembly × 1 — Use OEM specification
• Exhaust flange gasket kit × 1 — Dorman 60127 or equivalent
• Exhaust manifold gasket × 1 — Use OEM specification if manifold removed
• DPF pressure sensor differential hoses (if damaged) × 1 — Use OEM specification
• Exhaust hangers (if deteriorated) × 2 — Replace as needed

Preparation

1. Park vehicle on level ground and apply parking brake. Chock rear wheels.
2. Allow exhaust system to cool completely (minimum 2 hours after engine shutdown).
3. Raise front of vehicle and support securely on jack stands at frame rails.
4. Spray all exhaust flange bolts, hanger bolts, and O2 sensor threads with penetrating oil. Allow to soak for 15-30 minutes minimum.
5. Disconnect negative battery terminal to prevent fault codes during sensor disconnection.
6. Place drain pan under DPF area to catch any accumulated soot or condensation.

Procedure

1. 1

   Disconnect DPF sensors and wiring
   Locate the upstream and downstream exhaust gas temperature (EGT) sensors on the DPF canister. Press the locking tab and disconnect both electrical connectors. Disconnect the differential pressure sensor connector on the DPF housing. Carefully disconnect the two small pressure sensing tubes from the DPF by pressing the release collar and pulling straight out. Cap or plug open tube ends to prevent debris entry.
   ⚠The pressure sensing tubes are fragile. Do not bend or kink them during removal.
2. 2

   Remove heat shields
   Remove the heat shield bolts securing any heat shields covering the DPF assembly. There are typically 4-6 bolts depending on configuration. Set shields aside. Use a wire brush to clean exposed bolt holes and mating surfaces.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect upstream oxygen sensor
   Using an appropriate wrench or socket, carefully unthread the upstream exhaust gas temperature (EGT) sensor from the turbo outlet or DPF inlet pipe. Work slowly to avoid breaking the sensor. If sensor will be reused, inspect threads and apply fresh anti-seize to threads only (avoid contaminating the sensor tip).
   ⚠Never apply anti-seize to the oxygen sensor tip or ceramic element. Apply only to threads.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
4. 4

   Remove exhaust hanger supports
   Locate the rubber exhaust hangers supporting the DPF assembly (typically 2-3 locations). Remove the hanger bolts to free the DPF from its support points. You may need to use a pry bar to gently separate rubber hangers from their brackets. Support the DPF weight with a transmission jack or have an assistant hold it.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
5. 5

   Disconnect upstream exhaust flange
   Locate the exhaust flange connecting the turbo outlet or downpipe to the DPF inlet. Remove the flange bolts (typically 3 bolts in a triangular pattern). Gently pry the connection apart and remove the old gasket. Clean both flange surfaces thoroughly with a wire brush to remove carbon buildup.
   ⚠If bolts are severely corroded, apply additional penetrating oil and use a 6-point socket to minimize rounding. Heat may be required for stubborn bolts.
   Torque spec

   Exhaust Flange Bolt45 Nm (33 lb-ft)
6. 6

   Disconnect downstream exhaust flange
   Move to the rear of the DPF assembly and locate the flange connecting the DPF outlet to the intermediate exhaust pipe. Remove the flange bolts (typically 3 bolts). Separate the connection and remove the old gasket. Clean both flange surfaces thoroughly.
7. 7

   Remove DPF assembly
   With both flanges disconnected and hangers removed, carefully lower the DPF assembly from the vehicle. The unit is heavy and awkward, so work slowly. If using a transmission jack, lower it gradually. Tip the assembly as needed to clear frame rails and suspension components. Place the old DPF on a clean work surface.
   ⚠DPF assembly weighs 50-60 lbs. Use proper lifting techniques and get assistance to avoid injury or dropping the unit.
8. 8

   Prepare new DPF for installation
   Unpack the new DPF assembly and verify all sensor ports are present and undamaged. Transfer any reusable brackets or clamps from the old unit if not included with the new DPF. Install new exhaust flange gaskets on both the inlet and outlet flanges of the new DPF. If the torque specification allows lubricated threads, apply a thin coat of high-temp anti-seize to flange bolt threads; otherwise install dry per the torque spec basis.
9. 9

   Install new DPF assembly
   Raise the new DPF into position, aligning the inlet flange with the turbo outlet or downpipe connection. Support the DPF weight with a transmission jack or assistant. Align both upstream and downstream flanges, ensuring gaskets remain properly seated. Start all flange bolts by hand before tightening any of them.
10. 10

    Torque exhaust flanges
    Beginning with the upstream flange (turbo side), torque the exhaust flange bolts to specification in a star or crossing pattern to ensure even gasket compression. Then torque the downstream flange bolts in the same manner. Verify gaskets have not shifted during tightening.
    ℹ️Tighten in multiple passes (50% torque, then 100%) for best gasket sealing and to prevent bolt breakage.
    Torque spec

    Exhaust Flange Bolt45 Nm (33 lb-ft)
11. 11

    Reinstall exhaust hangers
    Align the DPF assembly with the rubber exhaust hangers. Install and torque the hanger bolts to specification. Ensure the DPF is properly supported and not placing stress on the flanges.
    Torque spec

    Hanger Bolts20 Nm (15 lb-ft)
12. 12

    Install oxygen sensor
    Apply anti-seize compound to the oxygen sensor threads only (do not contaminate the sensor tip). Thread the sensor by hand into the DPF inlet or turbo outlet until hand-tight, then torque to specification using a 22mm wrench or oxygen sensor socket.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
13. 13

    Reinstall heat shields
    Position heat shields over the DPF assembly and install heat shield bolts. Torque to specification. Ensure shields are not touching or rubbing against the DPF canister itself, allowing for thermal expansion.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
14. 14

    Reconnect sensors and wiring
    Reconnect both NOx/temperature sensor electrical connectors, ensuring they click into place. Reconnect the differential pressure sensor connector. Install the two pressure sensing tubes into their ports on the DPF housing, pushing until they click and lock into place. Verify all connections are secure and wiring is routed away from hot exhaust components.

Reassembly

1. Reconnect negative battery terminal.
2. Lower vehicle from jack stands and remove wheel chocks.
3. Perform a visual inspection under the vehicle to verify all connections are secure and no tools or parts were left behind.

Verification

• Start the engine and allow it to idle for 2-3 minutes. Listen for exhaust leaks at both flange connections.
• Inspect all flange connections while engine is running for visible exhaust gas leakage or soot deposits.
• Use a scan tool to verify DPF pressure sensors are reading correctly and no fault codes are present (may need to drive 10-15 miles for system to fully initialize).
• Perform a short test drive (5-10 miles) and re-check all connections for leaks after the exhaust system has heated and cooled through one cycle.
• Monitor DPF regeneration cycles over the next few days to ensure the new filter is functioning properly.

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