exhaust

Diesel Particulate Filter

for 2007 Ram 3500 5.9L I6 Cummins · 4WD

Difficulty

Moderate

Time

2.9 h

Tools

Steps

✓Fact-checked. Built from OLP's spec database, then independently fact-checked line by line with every correction applied. Master-tech sign-off by Chris Hackleman is queued. Cross-check torque values against the factory manual, and stop if anything looks unsafe. How our data is made.

This procedure covers the removal and replacement of the Diesel Particulate Filter (DPF) on a 2007 Ram 3500 with the 5.9L Cummins diesel engine.

Warnings

⚠️Allow the exhaust system to cool completely before starting work. Exhaust components can remain hot enough to cause severe burns for over an hour after engine shutdown.

⚠The DPF is heavy (approximately 40-50 lbs) and awkward to handle. Use proper lifting technique and have an assistant available.

⚠Do not drop or strike the DPF as the internal substrate is fragile and damage will require replacement.

ℹ️This vehicle uses the early generation DPF system. Ensure replacement DPF is compatible with 2007 model year specifications.

Tools required

Floor jack and jack standsEssential

Wheel chocksEssential

Socket set (metric)Essential

Wrench set (metric)Essential

Penetrating oilEssential

Exhaust hanger removal tool or pry bar

Wire brush

Torque wrenchEssential

Oxygen sensor socketEssential

Safety glassesEssential

Work glovesEssential

Anti-seize compound

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Parts

Diesel Particulate Filter (DPF) × 1 — Use OEM specification
DPF inlet gasket × 1 — Use OEM specification
DPF outlet gasket × 1 — Use OEM specification
Exhaust clamp hardware × 1 — Replace as needed
Differential pressure sensor (if faulty) × 1 — Use OEM specification

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Preparation

Park vehicle on level ground and apply parking brake
Place wheel chocks behind rear wheels
Allow exhaust system to cool completely (minimum 2 hours after last operation)
Disconnect negative battery cable to prevent codes during sensor disconnection
Spray all exhaust fasteners with penetrating oil and allow to soak for 15-30 minutes
Raise vehicle securely on jack stands at frame contact points to provide adequate working clearance
Remove any skid plates or belly pans that may obstruct access to the DPF

Procedure

1
Disconnect DPF sensors
Locate the differential pressure sensor on top of the DPF assembly. Disconnect the electrical connector by pressing the release tab. Trace the pressure sensor hoses from the sensor to the DPF inlet and outlet, and carefully disconnect them from the barbed fittings. Note their positions for reinstallation.
2
Disconnect exhaust temperature sensors
Locate the exhaust temperature sensors (one before and one after the DPF). Disconnect the electrical connectors. Using an oxygen sensor socket, carefully remove both temperature sensors from the exhaust pipe. These sensors are fragile; if they will be reused, handle with care and apply anti-seize to threads before reinstallation.
3
Remove DPF inlet connection
Locate the V-band clamp or flange connection at the inlet (front) of the DPF, where it connects to the turbocharger downpipe. Remove the clamp bolts or band clamp hardware. Separate the connection and remove the gasket. Inspect the mating flange for damage or warping.
4
Remove DPF outlet connection
Locate the connection at the outlet (rear) of the DPF where it connects to the tailpipe section. This may be a V-band clamp, flange, or slip-fit connection. Remove the fasteners and separate the connection. Remove and discard the gasket if equipped.
5
Support and remove DPF mounting brackets
Position a jack or have an assistant support the weight of the DPF assembly. Locate the mounting brackets that secure the DPF to the frame or transmission crossmember (typically 2-3 mounting points). Remove the mounting bracket bolts. Keep hardware organized as some brackets may use different length bolts.
⚠Ensure DPF is properly supported before removing final mounting bracket. The assembly can shift suddenly when freed.
6
Remove DPF from vehicle
Carefully maneuver the DPF assembly downward and out from under the vehicle. It may be necessary to angle the unit to clear frame rails and crossmembers. Work slowly to avoid damaging brake lines, fuel lines, or wiring harnesses in the area. Place the DPF on a clean work surface.
7
Inspect and clean mounting points
With the DPF removed, inspect all mounting brackets and exhaust hangers for damage, cracks, or excessive wear. Clean the inlet and outlet flange mating surfaces with a wire brush to remove carbon deposits and old gasket material. Inspect flanges for warping or damage that could cause exhaust leaks.
8
Prepare new DPF for installation
Remove the new DPF from packaging and verify all sensor ports are clear and undamaged. Install new inlet and outlet gaskets onto the DPF flanges. If reusing temperature sensors, apply a thin coat of anti-seize compound to the sensor threads (avoid getting anti-seize on the sensor tip).
9
Install new DPF assembly
With assistance or using a transmission jack, carefully raise the new DPF into position under the vehicle. Align the mounting bracket holes with the frame or crossmember mounting points. Install mounting bracket bolts hand-tight first to allow for alignment adjustment.
10
Connect inlet and outlet flanges
Align the DPF inlet flange with the turbocharger downpipe, ensuring the gasket is properly seated. Install the V-band clamp or flange bolts and tighten evenly in a cross-pattern to avoid warping the flange. Repeat for the outlet connection to the tailpipe section. Verify both connections are properly aligned before final tightening.
11
Tighten mounting brackets
With exhaust connections made, verify the DPF is properly aligned and not under stress. Torque all mounting bracket bolts securely. Verify there is adequate clearance around the DPF and that it is not contacting the frame, fuel tank, or driveline components.
12
Install sensors
Install the exhaust temperature sensors into their respective ports (inlet and outlet). Tighten carefully using the oxygen sensor socket; do not overtighten as the ports can strip. Reconnect electrical connectors to both temperature sensors. Install the differential pressure sensor into its mounting location and reconnect its electrical connector.
13
Connect pressure sensor hoses
Connect the differential pressure sensor hoses to the correct ports on the DPF (one at inlet, one at outlet). Ensure hoses are properly seated on the barbed fittings and not kinked or pinched. Verify hoses are routed away from hot exhaust components and moving parts.

Reassembly

Reinstall any skid plates or belly pans that were removed for access
Lower the vehicle from jack stands
Reconnect the negative battery cable
Double-check all electrical connections are secure and hoses are properly routed

Verification

Start the engine and allow it to reach normal operating temperature while monitoring for exhaust leaks at the DPF connections
Inspect all connections for visible exhaust smoke or soot indicating a leak
Use a scan tool to verify no DPF-related fault codes are present
Verify differential pressure sensor is reading properly (typically 0-2 psi at idle with clean DPF)
Perform a test drive and monitor exhaust system for unusual noises or vibrations
Re-inspect all connections after test drive for any signs of leaks or loosening
Clear any DPF-related codes that may have been stored during the repair process