DPF Clogged
More Turbo
Joined: Oct 2010
Posts: 587
Likes: 101
From: Nampa, Idaho
Understood, but was curious what they found since they also did the TSB.
I had my exhaust assembly replaced years ago by the dealership because of a leak, and they reused the sensors (one they didn't seat the plug completely). However, my truck had a lot fewer miles on it than the OP's.
I had my exhaust assembly replaced years ago by the dealership because of a leak, and they reused the sensors (one they didn't seat the plug completely). However, my truck had a lot fewer miles on it than the OP's.
Cross-Country
Joined: Feb 2013
Posts: 50
Likes: 3
From: Old Saybrook,Ct
Same issue with my truck(2011 DRW 90,000mi) Light tailpipe soot but runs great. No codes thrown at all. Dealer says it’s normal for tailpipe to have soot. Been running it like this for a few years now. Sounds like cracked DPF. But why no CEL?
Super Moderator
Joined: Aug 2008
Posts: 37,384
Likes: 1,868
From: Frederick, MD
you wont get a cel until it reaches a certain threshold of failure. I little grayish maybe normal because of the regen process.
If you take you 90K mile truck on the road for a trip of towing what do the pipes look like then?
How far apart are the regen cycles?
If you take you 90K mile truck on the road for a trip of towing what do the pipes look like then?
How far apart are the regen cycles?
Cross-Country
Joined: Feb 2013
Posts: 50
Likes: 3
From: Old Saybrook,Ct
Pipes stay the same even on trips to Florida with the camper on. Regens at about 300 -350 miles
I clean them occasionally but they soot up in a couple hundred miles. I’m the original owner. Been running Valvoline Premium Blue 05w-40 synthetic oil since1st year. Also Opti Lube additive.
I clean them occasionally but they soot up in a couple hundred miles. I’m the original owner. Been running Valvoline Premium Blue 05w-40 synthetic oil since1st year. Also Opti Lube additive.
Thread Starter
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Mountain Pass
Joined: Jul 2006
Posts: 221
Likes: 29
From: USA
Here I am 9 months and 5,802 miles since my last repair to my exhaust emissions system under warranty. In the last 15 months and approximately 10,000 miles the truck has been to the dealer 4 times for continued repairs to the exhaust emissions system. Early May the engine light came on but went off a few days later, I did not check the code busy with work. Mid June 2025 the engine light again illuminated checking the code resulted in P2002 code. I made an appointment with my dealer for July 2 and informed them of the P2002 code. I requested the dealer contact Ford for assistance in diagnosing the cause of the continuing failures, which did not happen. I also contacted Ford, requesting they assist my dealer who said they would make contact within 24 hours, which also did not happen. Received a call from dealer July 3rd informing me the DPF again needed to be replaced at my expense with an estimated cost of $7,500. Ford care did finally contact me July 7th and the dealer after repeated calls from me. The dealer informed Ford, that I opted to have a partial repair done but declined the DPF replacement. Not true, the other warranty repair was unrelated to the emission issues. The message I received from Ford states, for them to assist in diagnosing the cause of the continuing emission problem, I will need to pay for the DPF replacement prior to any effort by Ford to assist in diagnosis of the continuing emission failures. Again all at my expense to include their assistance in diagnosing the cause even though I have an active PremiumCARE warranty. I guess my PremiumCARE warranty is not worth the paper it’s written on. The warranty does exclude the DPF but all other emissions should be covered. Seems like, kick the can down the road until warranty expired on the DPF then it’s all my problem! Thanks a lot Ford! Below is a sequence of events.
1. 39,616 miles, 3-25-24 Sensor JC3Z-5L239-C and tail pipe replaced
2. 40,451 miles, 4-23-24 DPF replaced, I believe TSB 21-2332 completed. (Not sure as I am out of town and unable to retrieve the paperwork)
3. 44,298 miles, 9-19-24 sensor HC3Z-5L248-A replaced
4. 50,100 miles estimate not sure too pissed to look when I dropped it off, 7-3-25 P2002 DPF needs to be replaced again NICE!
If anyone has any suggestions or any insight on why the exhaust emission failures continue, please respond. Thank You!
1. 39,616 miles, 3-25-24 Sensor JC3Z-5L239-C and tail pipe replaced
2. 40,451 miles, 4-23-24 DPF replaced, I believe TSB 21-2332 completed. (Not sure as I am out of town and unable to retrieve the paperwork)
3. 44,298 miles, 9-19-24 sensor HC3Z-5L248-A replaced
4. 50,100 miles estimate not sure too pissed to look when I dropped it off, 7-3-25 P2002 DPF needs to be replaced again NICE!
If anyone has any suggestions or any insight on why the exhaust emission failures continue, please respond. Thank You!
Laughing Gas
Joined: Dec 2016
Posts: 781
Likes: 188
From: Knightstown Indiana
Man, definitely sucks. How competent is your dealer? I would ask if they have any Senior Master Service techs, if not, go somewhere else. The first cracked dpf substrate could be chocked up to manufacturing error, a second points to another issue within the truck.
I will be corrected if I’m wrong, but as I understand EGT sensor 4 regulates the regen process. You could have a bad EGT sensor that is functional, but not correct and you are over baking during the regen causing the dpf failures. An experienced tech can/will look at all four to see if temperatures of the system are responding as they should. Possibly a static regen could be performed so they can be verified with other equipment.
In my opinion this is a service/diagnostic issue that your current dealer is not capable of handling.
I will be corrected if I’m wrong, but as I understand EGT sensor 4 regulates the regen process. You could have a bad EGT sensor that is functional, but not correct and you are over baking during the regen causing the dpf failures. An experienced tech can/will look at all four to see if temperatures of the system are responding as they should. Possibly a static regen could be performed so they can be verified with other equipment.
In my opinion this is a service/diagnostic issue that your current dealer is not capable of handling.
FTE Legend
Joined: Mar 2017
Posts: 31,967
Likes: 9,197
From: Western NY
Here I am 9 months and 5,802 miles since my last repair to my exhaust emissions system under warranty. In the last 15 months and approximately 10,000 miles the truck has been to the dealer 4 times for continued repairs to the exhaust emissions system. Early May the engine light came on but went off a few days later, I did not check the code busy with work. Mid June 2025 the engine light again illuminated checking the code resulted in P2002 code. I made an appointment with my dealer for July 2 and informed them of the P2002 code. I requested the dealer contact Ford for assistance in diagnosing the cause of the continuing failures, which did not happen. I also contacted Ford, requesting they assist my dealer who said they would make contact within 24 hours, which also did not happen. Received a call from dealer July 3rd informing me the DPF again needed to be replaced at my expense with an estimated cost of $7,500. Ford care did finally contact me July 7th and the dealer after repeated calls from me. The dealer informed Ford, that I opted to have a partial repair done but declined the DPF replacement. Not true, the other warranty repair was unrelated to the emission issues. The message I received from Ford states, for them to assist in diagnosing the cause of the continuing emission problem, I will need to pay for the DPF replacement prior to any effort by Ford to assist in diagnosis of the continuing emission failures. Again all at my expense to include their assistance in diagnosing the cause even though I have an active PremiumCARE warranty. I guess my PremiumCARE warranty is not worth the paper it’s written on. The warranty does exclude the DPF but all other emissions should be covered. Seems like, kick the can down the road until warranty expired on the DPF then it’s all my problem! Thanks a lot Ford! Below is a sequence of events.
1. 39,616 miles, 3-25-24 Sensor JC3Z-5L239-C and tail pipe replaced
2. 40,451 miles, 4-23-24 DPF replaced, I believe TSB 21-2332 completed. (Not sure as I am out of town and unable to retrieve the paperwork)
3. 44,298 miles, 9-19-24 sensor HC3Z-5L248-A replaced
4. 50,100 miles estimate not sure too pissed to look when I dropped it off, 7-3-25 P2002 DPF needs to be replaced again NICE!
If anyone has any suggestions or any insight on why the exhaust emission failures continue, please respond. Thank You!
1. 39,616 miles, 3-25-24 Sensor JC3Z-5L239-C and tail pipe replaced
2. 40,451 miles, 4-23-24 DPF replaced, I believe TSB 21-2332 completed. (Not sure as I am out of town and unable to retrieve the paperwork)
3. 44,298 miles, 9-19-24 sensor HC3Z-5L248-A replaced
4. 50,100 miles estimate not sure too pissed to look when I dropped it off, 7-3-25 P2002 DPF needs to be replaced again NICE!
If anyone has any suggestions or any insight on why the exhaust emission failures continue, please respond. Thank You!
Sensor JC3Z-5L239-C is the diesel particulate sensor. I'd assume it was corroded into the tailpipe, hence the tailpipe replacement... what was the CEL code that prompted the replacement and what was the truck doing?
I'll do a deeper dive for you to help you out but need more information on the codes thrown.
How did you drive your truck prior to these issues? Lots of stop and go and short trips? Do active regens complete? Obviously your truck sits a lot... how often?
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Thread Starter
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Mountain Pass
Joined: Jul 2006
Posts: 221
Likes: 29
From: USA
Superdave71 you are correct. Not much idle time just enough to let things cool off. Not used around town I have a car for that. For the past year been remodeling a house that is 3.5 to 4 hours away pulling a 12,000-dump trailer with a skid loader much of the time. Purchased the house in February of 24 so all of the failures have happened during these travels back and forth. Had a 2 month stay here in Virginia, if I was back in Maryland the truck would have been back at the dealer when the engine light lit in May. Would have been a warranty issue then no questions asked. But that didn't happen, water over the dam.
This go around the question I asked my dealer when making the appointment was if they had a qualified Tec diesel certified in emissions. Their answer was they had several, which seemed evasive to me. I then asked to speak with the shop foreman and was denied. That was the reason I contacted Ford who told me they would work with the dealer to figure things out. The only contact Ford made with the dealer was to speak to the service writer. Many years ago I was Master Certified Ford tech and also ASE Master Certified. While I do not pretend to know current technology, I do have an understanding of the way things work. My first car was a 1966 Ford Mustang in 1971. All Fords since with my first new truck purchased 1979 F150 4x4 purchased while employed at a Ford dealer as a mechanic. Nothing but Ford trucks since, all bought new. This might be the last.
This go around the question I asked my dealer when making the appointment was if they had a qualified Tec diesel certified in emissions. Their answer was they had several, which seemed evasive to me. I then asked to speak with the shop foreman and was denied. That was the reason I contacted Ford who told me they would work with the dealer to figure things out. The only contact Ford made with the dealer was to speak to the service writer. Many years ago I was Master Certified Ford tech and also ASE Master Certified. While I do not pretend to know current technology, I do have an understanding of the way things work. My first car was a 1966 Ford Mustang in 1971. All Fords since with my first new truck purchased 1979 F150 4x4 purchased while employed at a Ford dealer as a mechanic. Nothing but Ford trucks since, all bought new. This might be the last.
FTE Legend
Joined: Mar 2017
Posts: 31,967
Likes: 9,197
From: Western NY
Superdave71 you are correct. Not much idle time just enough to let things cool off. Not used around town I have a car for that. For the past year been remodeling a house that is 3.5 to 4 hours away pulling a 12,000-dump trailer with a skid loader much of the time. Purchased the house in February of 24 so all of the failures have happened during these travels back and forth. Had a 2 month stay here in Virginia, if I was back in Maryland the truck would have been back at the dealer when the engine light lit in May. Would have been a warranty issue then no questions asked. But that didn't happen, water over the dam.
This go around the question I asked my dealer when making the appointment was if they had a qualified Tec diesel certified in emissions. Their answer was they had several, which seemed evasive to me. I then asked to speak with the shop foreman and was denied. That was the reason I contacted Ford who told me they would work with the dealer to figure things out. The only contact Ford made with the dealer was to speak to the service writer. Many years ago I was Master Certified Ford tech and also ASE Master Certified. While I do not pretend to know current technology, I do have an understanding of the way things work. My first car was a 1966 Ford Mustang in 1971. All Fords since with my first new truck purchased 1979 F150 4x4 purchased while employed at a Ford dealer as a mechanic. Nothing but Ford trucks since, all bought new. This might be the last.
This go around the question I asked my dealer when making the appointment was if they had a qualified Tec diesel certified in emissions. Their answer was they had several, which seemed evasive to me. I then asked to speak with the shop foreman and was denied. That was the reason I contacted Ford who told me they would work with the dealer to figure things out. The only contact Ford made with the dealer was to speak to the service writer. Many years ago I was Master Certified Ford tech and also ASE Master Certified. While I do not pretend to know current technology, I do have an understanding of the way things work. My first car was a 1966 Ford Mustang in 1971. All Fords since with my first new truck purchased 1979 F150 4x4 purchased while employed at a Ford dealer as a mechanic. Nothing but Ford trucks since, all bought new. This might be the last.
1. 39,616 miles, 3-25-24 Sensor JC3Z-5L239-C and tail pipe replaced
2. 40,451 miles, 4-23-24 DPF replaced, I believe TSB 21-2332 completed. (Not sure as I am out of town and unable to retrieve the paperwork)
3. 44,298 miles, 9-19-24 sensor HC3Z-5L248-A replaced
4. 50,100 miles estimate not sure too pissed to look when I dropped it off, 7-3-25 P2002 DPF needs to be replaced again NICE!
I'm no mechanic or an expert, but they replace the diesel particulate sensor and about 4k miles they replace the DPF under TSB 21-2332
which states:
"Some 2017-2020 Super Duty vehicles equipped with a 6.7L built on or after 13-May-2017, 2015-2019 Transit vehicles equipped with a 3.2L and 2018-2020 F-150 vehicles equipped with a 3.0L may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P2002 stored in the
powertrain control module">
powertrain control module" /> powertrain control module">powertrain control module
(
). This may be due to a crack in the
powertrain control module" /> powertrain control module">powertrain control module
diesel particulate filter">diesel particulate filter" /> diesel particulate filter">diesel particulate filter
(
) substrate. To correct the condition, follow the Service Procedure steps to replace the
and then reprogram the
."diesel particulate filter" /> diesel particulate filter">diesel particulate filter
Then 4k miles later, they throw a NOx sensor at it, which I'd assume that since 5k miles later, it's throwing another P2002 code, which could have thrown off the NOx sensor if the new DPF is once again cracked but I wonder if they reprogrammed the PCM the first time? I'm no expert nor a Ford tech and you work the truck, this schitt makes zero sense. All that's different the second time around is a different sensor... could the first DPF replacement have been defective and/or did somebody not reprogram the PCM?
Here's a P2002 link with info. And another link here.
Here's a link from @Beard Ford Tech maybe more info there.
Did your exhaust tips have any soot on them?
Good luck.
Thread Starter
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Mountain Pass
Joined: Jul 2006
Posts: 221
Likes: 29
From: USA
Overkill2 Thanks for the information! I have read and understand the TSB 21-2332 which was listed on the invoice during the last replacement of the DPF. Actually I handed them the TSB when I dropped the truck off for the first DPF replacement. Weather it was actually done or not, I don't know. My build date is 04/18/18 so I would be included in the TSB. None of this makes sense to me. Truck ran great on my 3.5 hour trip back to my dealer with about 19mpg but my exhaust tips were sooted over coal black. Supposedly I am to receive a call back from Ford customer care today, we'll see. In the video he states if you have PremiumCARE warranty (which I do) it should be covered. Ford customer care informed me it is not covered. I have a call into Two Rivers Ford who I purchased the warranty from to see what they say about the coverage. I don't have high hopes. I also feel the Tech has not investigated fully what is causing the failures. What realy gets me is Ford stating I must pay the $7,500 prior to them completing any further diagnosis which they also stated I will pay for.
I have purposely had my dealer complete all services since day one right down to purchasing my tires from them. Many of the maintenance items were been done considerably earlier than required by the maintenance manual. Back when I was employed as a mechanic at dealerships, if there was a problem vehicle where a factory rep got involved, the first thing they asked to see was the service records. A customer who only came to the dealer for warranty issues was viewed completely differently then one who completed services at a dealership. Not sure what my next steps are going to be? I find this whole thing to be unbelievable and completely unfair.
I have purposely had my dealer complete all services since day one right down to purchasing my tires from them. Many of the maintenance items were been done considerably earlier than required by the maintenance manual. Back when I was employed as a mechanic at dealerships, if there was a problem vehicle where a factory rep got involved, the first thing they asked to see was the service records. A customer who only came to the dealer for warranty issues was viewed completely differently then one who completed services at a dealership. Not sure what my next steps are going to be? I find this whole thing to be unbelievable and completely unfair.