New member – long time lurker. I will get right to the point as I am in a bind. Cold side intercooler pipe “popped” which should be no problem but I was on a narrow two-lane highway Northwest of Amarillo. I was towing my 38’ Fifth Wheel Toy Hauler at the time and with no place on the two-lane to safely pull off. I had to drive several miles before I finally reached a passing lane and was able to pull over on the shoulder. The truck showed no check engine light until I stopped.
Now the problem - all the wires that connect to the DPF are burnt off. Also noticed the DPF had a “hot” spot at the rear of the DPF on the upper passenger side. Had the truck towed to the nearest dealer and the RV to a RV park.
Dealer is telling me that Ford told them not to work on the truck until a Ford Engineer looks at it. Was told this was because of the “fire”. I am being told that this may take as long as three weeks.
From my forum searches the “popped” intercooler pipe is a common problem. But, the burnt DPF wiring is not. Truck had just turned over 45,000 miles with no previous problems.
Has anybody heard of this happening before? How many other problems with the truck can I expect? Is this something that should be covered under warranty. I might add that I am 250 miles from home, retired and on a fixed income so any major repairs will be a big deal.

 

The CAC pipe is quite popular and an easy fix, the DPF sensor, I've not heard of that one at all. As far as the rest of the truck. no big problems as of yet outside to the '11 valves and the turbos on the '11-'13 giving sporadic problems. For the most part, these trucks are rock solid. Ford did however reprogram the trucks so they would not shut down if an exhaust gas temperature sensor went out. Wonder if there was a short at the sensor?

 

The DPF (diesel particulate filter) is part of the exhaust system so I don't understand exactly what the problem is. A hot spot on the passenger side?

 

When you say DPF wires, are you speaking of the wires to the sensors on the exhaust? Or are you refering to the wires that plug in to the MAF sensor on the CAC tube? What you are talking about are not related. Maybe a photo if you can post it would really help!

 

What year is your truck?

Since you/they are waiting up to 3 weeks for an engineer to show up, did you ask them to loan you a truck to tow your 5th wheel?

Sounds like the catalytic converter had a melt down.

 

Very odd, but I have an opinion. I'm thinking the two issues are 100% related. While I have a very hard time believing that the engine wouldn't sense a lack of boost after the tube let go and defuel, it sure sounds like that's what happened. Engine expects x amount of air coming in from turbo. Mass air sensor is pre turbo so it is none the wiser. Continuing to drive it with a severe lack of expected airflow, and a heavy load caused the DPF to get so damn hot due to lack of airflow that it melted down.

Or lack of airflow caused so much smoke, that it face plugged the DPF and triggered a regen and again, due to lack of airflow, meltdown occured.

Just a guess, but I think that's where this will go.

 

I'm with you on this one.

 

Sorry – I left out the most important details on my first post. The truck is a 2014 6.7L Ultimate Lariat F350 DRW.
I have had the reprogram done so it would not shut down if an exhaust gas temperature sensor went out.

 

Yea, now that you mention that, when I had a pop-off on my 2011, I now recall EGT's getting pretty high. We were towing our old TT at the time, and it was still up over 1000 degrees. We were able to limp home at the time as well, just a lot slower.