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The invoices say that the DPF is completely plugged and was replaced both times with a new unit. The warning was DPF was full, drive to clean. There was no limp mode, no reduced power, it went down completely and would not restart until I took the pipe apart from the header
Yes it had 10 miles on it when we picked it up and it uses no oil. I think you are right about it not letting it regen. I'm hoping 3rd times a charm.
You should have DTCs for this issue or at least stored ones. If a regen is interrupted and the DPF is still in degraded mode, it's supposed to force another regen at 150 miles. Ask the tech what the active regeneration interval is with your truck. For the 2011 I know it stores the two most recent events so that the PCM can calculate average distance which is also used to determine if there is or isn't an issue. I don't know if it saves more than that though or if Ford configured IDS to lookup the regeneration event value.
It's not looking like a third will fix anything long term based on your experience so far. I doubt they're throwing parts at it though because Ford won't allow the dealer to just replace a $4,500 part without pinpoint testing.
the regen process requires the vehicle achieves normal operating temp before it starts to regen.....then the regen duration will vary. if you do short trips most of the time...you will never succeed in doing a regen.
cetane boost additives will help reduce soot...soot is what the exhaust filter captures
there is a monitoring tool called forscan and it can be setup to check your DPF regen status.....and it can do what is called an operator commanded regen.
the theoretical automatic regen is 500 miles...if you dirve 500 miles you should check your regen status and if DPF is full...initiate an operator commanded regen.
this regen complexity is one of the things that makes owning a diesel difficult...especially if you do a lot of low speed stop and go driving (metro area driving).