DPF Delete Pipe

This procedure removes the factory diesel particulate filter (DPF) and replaces it with a straight-through delete pipe on a 2007 Ram 3500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• DPF delete pipe kit (4-inch diameter for 5.9L Cummins) × 1 — Aftermarket DPF delete pipe specific to 2007 Ram 3500 5.9L
• Exhaust band clamps or V-band clamps × 2 — Typically 4-inch size, usually included with delete kit
• Exhaust gaskets × 2 — High-temperature exhaust gaskets for turbo outlet and tailpipe connection
• Differential pressure sensor eliminator or plug kit × 1 — DPF sensor delete plugs or simulators

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely (minimum 2 hours after last engine operation)
4. Spray all exhaust clamp bolts, DPF mounting bolts, and oxygen sensor threads with penetrating oil and allow to soak for at least 30 minutes
5. Raise front of vehicle using floor jack and secure on jack stands at frame rails
6. Raise rear of vehicle and secure on jack stands to provide level working position underneath
7. Verify vehicle is stable and will not shift during work

Procedure

1. 1

   Disconnect differential pressure sensor
   Locate the differential pressure sensor mounted on or near the DPF canister. Disconnect the electrical connector by pressing the release tab and pulling straight out. On 2007 models, this sensor has two hoses running to different points on the DPF - carefully disconnect these hoses at the sensor end. Label or photograph connections if needed for reference. Aftermarket DPF delete pipe specific to 2007 Ram 3500 5.9L Cummins — verify exact part number and fitment with the manufacturer before ordering.
2. 2

   Remove downstream oxygen sensor
   Locate the exhaust gas temperature (EGT) sensors along the exhaust/DPF assembly (this diesel does not use oxygen sensors). Disconnect the EGT sensor electrical connectors and, using the appropriate wrench, remove any EGT sensors threaded into the DPF section being removed. The sensors may be difficult to turn due to carbon and heat seizing; apply penetrating oil and gentle heat if necessary. Store sensors in a safe location if keeping for future use or if the delete pipe provides relocation ports.f keeping for future use.
3. 3

   Disconnect exhaust at turbo outlet
   Locate the V-band clamp or bolted connection between the turbocharger downpipe and the DPF inlet. If equipped with V-band clamp, loosen the clamp bolt and work the clamp off the flange. If equipped with bolted flange, remove the flange bolts (verify actual count and size on your vehicle before purchasing tools). Carefully separate the connection - you may need to rotate or wiggle the DPF assembly to break it free from the turbo outlet. Support the DPF assembly to prevent it from dropping.
4. 4

   Disconnect exhaust at tailpipe connection
   Move to the rear connection point where the DPF outlet connects to the intermediate exhaust pipe or muffler. Remove the band clamp or flange bolts securing this connection. On most 2007 Ram 3500 configurations, this will be a slip-fit connection with a band clamp. Loosen the clamp completely and pull the sections apart. A twisting motion may help break the connection free.
5. 5

   Remove DPF hanger brackets
   Locate the rubber exhaust hangers supporting the DPF canister assembly (typically two hangers along the length). Using a pry bar or by hand, work the hanger loops off the rubber isolators. The DPF assembly is heavy (approximately 40-60 lbs), so have a helper or use a jack to support the weight as you remove the last hanger connection.
6. 6

   Remove DPF assembly from vehicle
   With all connections and hangers released, carefully lower and remove the entire DPF assembly from the vehicle. Maneuver it out from under the truck, being careful not to damage brake lines, fuel lines, or wiring harnesses. Set aside in a safe location.
7. 7

   Clean and inspect connection points
   Using a wire brush, thoroughly clean the turbo outlet flange and the tailpipe connection point. Remove all carbon deposits, old gasket material, and rust. Inspect both flanges for cracks, warping, or damage. Clean the threads on any reusable bolts or studs. Apply anti-seize compound to all bolt threads that will be reinstalled.
8. 8

   Install new gasket at turbo outlet
   Position a new high-temperature exhaust gasket on the turbocharger outlet flange. Ensure the gasket is properly aligned with all bolt holes and the exhaust opening. Apply a thin coating of anti-seize to the gasket if recommended by the delete pipe kit manufacturer.
9. 9

   Install DPF delete pipe
   With assistance or using a jack for support, position the DPF delete pipe assembly under the vehicle. Align the inlet end with the turbocharger outlet flange and the outlet end with the tailpipe connection. The delete pipe should route in approximately the same path as the original DPF. Install but do not fully tighten the front connection (V-band clamp or bolts) to allow for alignment adjustment.
10. 10

    Connect delete pipe to tailpipe
    At the rear connection, install the provided gasket or sealing component if applicable. Slide the delete pipe outlet into the intermediate pipe connection and install the band clamp or V-band clamp. Position the clamp at the center of the overlap section. Snug but do not fully tighten to allow for final alignment.
11. 11

    Install exhaust hangers
    Connect the delete pipe to the rubber exhaust hangers using the provided brackets or the existing hanger points. Ensure the pipe is properly supported and not placing stress on the turbo outlet or tailpipe connections. The exhaust system should hang naturally without being forced into position.
12. 12

    Final alignment and tightening
    Check the entire delete pipe installation for proper alignment, clearance from frame rails, driveshaft, fuel tank, and all other components. Verify minimum 1-inch clearance all around. Once satisfied with positioning, tighten the front connection at the turbo outlet, then the rear connection at the tailpipe, and finally the intermediate clamps if present. Work from front to back. Torque all clamps strictly to the values specified in your delete kit's instructions, as no factory specifications apply to aftermarket clamps. Do not guess torque values — over-tightening a V-band clamp can crush the flange and under-tightening will cause leaks.
13. 13

    Install differential pressure sensor eliminator
    Install the differential pressure sensor delete plugs or simulator module according to the kit instructions. If using plugs, thread them into the ports on the delete pipe (if provided) or cap off the original sensor harness. If using an electronic simulator, install per manufacturer directions and connect to the vehicle harness. Secure all wiring away from heat and moving components.
14. 14

    Program ECM for DPF delete
    Using the appropriate tuning device or programmer, install the DPF delete tune to the engine control module. This is critical to prevent fault codes and limp mode. Follow the programmer's instructions exactly. Most tuners will remove DPF regeneration cycles, disable the differential pressure sensor monitoring, and adjust fueling parameters. Verify the tune is specific to 2007 Ram 3500 5.9L Cummins with DPF delete.

Reassembly

1. No disassembly of other components was required for this procedure

Verification

• Lower vehicle from jack stands and remove wheel chocks
• Start engine and listen for exhaust leaks at all connection points - a hissing sound indicates a leak that must be corrected
• Check for check engine light or fault codes using a scan tool - address any codes related to exhaust sensors
• Verify differential pressure sensor code is not present (should be disabled by tune)
• Allow engine to reach operating temperature and verify no abnormal smoke or behavior
• Perform a test drive and confirm normal operation with no limp mode or power loss
• After first 50 miles, re-check all exhaust clamp tightness as thermal cycling may cause settling
• Visually inspect underneath vehicle for proper clearance and no contact with frame or drivetrain components

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