This procedure covers the removal and replacement of the Diesel Particulate Filter (DPF) on a 2014 Ram 2500 with the 6.7L Cummins diesel engine, including disconnection of sensors and exhaust components.

Warnings

Tools required

Parts

• Diesel Particulate Filter (DPF) × 1 — Use OEM specification
• DPF gasket kit × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Use OEM specification
• Differential pressure sensor O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely (minimum 3 hours after operation)
4. Raise vehicle using heavy-duty jack and secure on jack stands rated for vehicle weight
5. Ensure adequate working height beneath vehicle (minimum 24 inches recommended)
6. Spray all exhaust flange bolts, hanger bolts, and sensor threads with penetrating oil and allow to soak for 15-30 minutes
7. Disconnect negative battery terminal to prevent electrical faults during sensor removal

Procedure

1. 1

   Remove heat shields and covers
   Locate and remove the heat shields protecting the DPF assembly. Remove all cover screws securing the shields. There are typically multiple shields covering the DPF and surrounding exhaust components. Set shields aside in a clean area.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect differential pressure sensor lines
   Locate the differential pressure sensor on top of the DPF housing. Carefully disconnect the electrical connector by pressing the release tab. Remove the two pressure sensing lines from the DPF inlet and outlet ports. Mark or photograph sensor orientation for reinstallation. Inspect O-rings and replace if damaged.
   ⚠Pressure sensor lines are fragile. Do not bend or kink the tubes during removal as this will affect sensor accuracy.
3. 3

   Remove upstream oxygen sensor
   Locate the NOx sensor or oxygen sensor upstream of the DPF. Disconnect the electrical connector. Using an oxygen sensor socket, carefully remove the sensor by turning counterclockwise. If sensor is seized, apply additional penetrating oil and allow to soak, then use controlled force to avoid breaking sensor in housing.
   ⚠Oxygen sensors are extremely fragile. Never use excessive force or impact tools as this will damage the sensor. A broken sensor in the housing requires much more extensive repair.
   Torque spec

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

   Remove downstream oxygen sensor
   Locate the downstream oxygen sensor or NOx sensor after the DPF assembly. Disconnect the electrical connector. Using an oxygen sensor socket, remove the sensor by turning counterclockwise. Store sensor in a clean, safe location where it cannot be impacted or contaminated.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
5. 5

   Disconnect inlet exhaust flange
   Locate the exhaust flange connection between the diesel oxidation catalyst (DOC) and the DPF inlet. Remove the flange bolts securing this connection. Once bolts are removed, carefully separate the flanges. Remove and discard the old gasket. Clean both mating surfaces with a wire brush to remove carbon deposits and old gasket material.
   ⚠If bolts are severely corroded and break during removal, you may need to drill out broken studs and install thread repair inserts before reassembly.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Disconnect outlet exhaust flange
   Locate the exhaust flange connection between the DPF outlet and the downstream exhaust pipe. Remove all exhaust flange bolts securing this connection. Apply anti-seize compound to bolt threads during removal for future serviceability. Separate the flanges and remove the old gasket. Clean both mating surfaces thoroughly.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Remove exhaust hanger supports
   Locate all rubber exhaust hangers supporting the DPF assembly. There are typically 2-3 hangers along the DPF body. Remove the hanger bolts or use an exhaust hanger removal tool to slip the rubber isolators off their mounting studs. Support the DPF weight as you remove the final hanger.
   ⚠️Have an assistant support the DPF assembly weight before removing the final hanger. The assembly weighs over 60 lbs and will drop suddenly if not supported.
   Torque spec

   Hanger Bolts27 Nm (20 lb-ft)
8. 8

   Remove DPF assembly mounting brackets
   With the DPF supported, locate and remove all mounting bolts securing the DPF brackets to the vehicle frame or crossmember. There are typically 2-4 mounting points. Keep track of all mounting hardware, spacers, and bracket orientation for proper reinstallation.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
9. 9

   Lower and remove DPF assembly
   With an assistant supporting the opposite end, carefully lower the DPF assembly from the vehicle. Maneuver the assembly past any obstructions, taking care not to impact the housing or remaining exhaust components. Place the DPF on a clean, padded surface. Inspect the removed DPF for physical damage, cracks, or evidence of internal substrate failure.
   ⚠Use proper lifting techniques with legs, not back. The DPF is awkward and heavy. Consider using a transmission jack to assist with lowering the assembly.
10. 10

    Prepare new DPF for installation
    Unpack the new DPF assembly and inspect for shipping damage. Verify all pressure sensor ports are present and undamaged. Install new O-rings on differential pressure sensor ports using a light coating of clean engine oil. Verify oxygen sensor bungs are clean and free of debris. Install new gaskets on both inlet and outlet flanges.
    ℹ️Do not remove any protective caps or plugs from the DPF until immediately before installation to prevent contamination.
11. 11

    Install new DPF assembly
    With an assistant, carefully lift the new DPF assembly into position beneath the vehicle. Align mounting brackets with frame mounting points. Install mounting bolts finger-tight initially. Reconnect exhaust hangers to their rubber isolators or mounting studs. Ensure proper alignment of inlet and outlet flanges before proceeding.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)

    Hanger Bolts27 Nm (20 lb-ft)
12. 12

    Connect exhaust flanges
    Install new flange gaskets at both inlet and outlet connections. Align flanges carefully to avoid gasket damage. Install flange bolts with anti-seize compound applied to threads. Start all bolts finger-tight, then tighten in a cross-pattern to ensure even gasket compression. Torque inlet flange bolts first, then outlet flange bolts to specification.
    ℹ️Apply anti-seize only to bolt threads, not to gasket surfaces or flange faces. Tighten in multiple passes using a cross-pattern to prevent warping.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Install oxygen sensors
    Apply anti-seize compound to oxygen sensor threads only, being extremely careful not to contaminate the sensor tip. Thread both upstream and downstream sensors by hand into their respective bungs until finger-tight. Use oxygen sensor socket and torque wrench to tighten to specification. Reconnect electrical connectors to both sensors, ensuring positive clicks.
    ⚠Never apply anti-seize to sensor tips or allow any contamination of the sensing element. Even small amounts of oil or anti-seize on the sensor tip will cause permanent sensor failure.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
14. 14

    Reconnect differential pressure sensor
    Install the differential pressure sensor lines to the inlet and outlet ports on the DPF. Ensure lines are not kinked, twisted, or in contact with hot exhaust surfaces. Reconnect the electrical connector to the pressure sensor. Verify secure connection by gently tugging on connector.
    ℹ️Route sensor lines away from heat sources and moving components. Lines must be free of kinks for accurate pressure readings.
15. 15

    Reinstall heat shields and perform final checks
    Reinstall all heat shields in reverse order of removal. Torque cover screws and heat shield bolts to specification. Perform a visual inspection of all connections, verifying all bolts are tight, sensors are connected, and no tools or parts remain in the work area. Reconnect negative battery terminal.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify all exhaust hangers are properly seated in rubber isolators
3. Ensure no wiring or hoses contact hot exhaust surfaces
4. Confirm all heat shields are properly installed to prevent heat damage to vehicle components

Verification

• With vehicle still raised, start engine and visually inspect all exhaust connections for leaks while engine warms up
• Listen for exhaust leaks at flange connections - any hissing indicates improper sealing
• Verify no exhaust contact or rattles against frame, driveshaft, or body components
• Using a scan tool, verify differential pressure sensor is reading and no DPF-related fault codes are present
• After lowering vehicle, perform a short test drive and monitor exhaust system for leaks, abnormal sounds, or check engine light
• After test drive, re-inspect all connections while exhaust is hot for any signs of leakage or loosening
• Verify DPF regeneration system operates normally using scan tool or by monitoring exhaust temperature and engine behavior

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