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I was thinking the crack would be on the outside and would allow either air into it or exhaust out of it and mess with the cleaning process.
Possible but you would see a soot stain on the outside of the exhaust pipe. However, that would not cause the tailpipe to blow smoke or soot up. All of the failures I have heard of are the filter inside of the canister cracks and then the soot passes thru the point of least ristriction (i.e. the crack).
Here is a cutaway view of a DPF filter off of a 2008 6.4L PSD. You can see that the filter medium is rather restrictive as well as fragile. There are many things that can cause the filters to fail but most of them are related to the addition of tuning devices and intake/ exhaust modifications or running unapproved fuel additives or the use fuels other than ULSD (15ppm Sulfer or less).
Did you buy the truck from a private party or from a dealer? If from a private party, do you think the previous owner would be willing to tell you if he had installed a tuner or any other modifications or not? Doesn't hurt to ask....
Many of the tuners for the 6.4L PSD engines do not require any hard wiring but rather connect to the OBD II diagnostic port and alter the ECM, TCM, and ICM module(s) programing. These can be removed without any traces of previous installation unless you have the proper diagnostic tools and even then, some claim they are still untraceable.
This second image is what you should see if the actual DPF canister had a crack in the exterior....
Here is a link to a video that explains the theory of a DPF equiped system and shows the inside of a typical DPF filter....
Bought it from a wholesaler in Dallas. It pretty much sat there until I bought it. I looked it over real well before I bought it. I saw the mileage report when the wholesaler bought it and the mileage when I drove it and it wasn't much difference. The exhaust looked untampered as did the intake.
Tried to call the owner and he's never returned calls. Not really sure if it was chipped or not.
I'm going to let the dealer have one last go at it. Once I iron out a few bugs with my 7.3 this one will be for sale.
I honestly can't figure out how you would be able to monitor a dripping injector.
I feel your pain. After 14,500 miles, a DPF, CAC, EGR, and a radiator I sold my '08 6.4 and bought a clean, low mileage 7.3. Had a John Wood Tranny, a 6.0 trans cooler, gauges, 4" turbo back exhaust and a DP Tuner installed and it performs as well as my 6.4 did and gets much better mileage. Best of all there is nothing but a muffler behind the turbo.
Bought it from a wholesaler in Dallas. It pretty much sat there until I bought it. I looked it over real well before I bought it. I saw the mileage report when the wholesaler bought it and the mileage when I drove it and it wasn't much difference. The exhaust looked untampered as did the intake.
Tried to call the owner and he's never returned calls. Not really sure if it was chipped or not.
Well, I guess we can rule out knowing the real history of the truck then. I would still be suspect of the DPF having a crack internally. Pretty common problem on the 2008's. I would try my darndest to get the dealer to replace the DPF filter under the emissions warranty. I would go to several dealers and one of them will do it for you. It is a very easy swap so the mechanic shouldn't be looking for reasons why not to do it (AS LONG AS IT IS STOCK). The bottom line is the DPF is there to remove the soot before it reaches the outside air. Yours is not doing this and it is an emmisions regulation for it to reduce the soot emissions by 90% from the model year 2006 standard. Here is a Ford Service message (Oasis) telling mechanics to look for certain codes or signs of modifications that could have caused a broken DPF. Read the second sentance pertaining to symptoms of a broken DPF/DOC (disregard the highlighted comments in yellow since you know the exhaust is all stock)
Any soot at all in the tail pipe - especially coming back right after cleaning them means your DPF is cracked or damaged. It needs to be replaced. End of story.
You either need to force your dealer to do it, or find another one that is more willing.
Any soot at all in the tail pipe - especially coming back right after cleaning them means your DPF is cracked or damaged. It needs to be replaced. End of story.
You either need to force your dealer to do it, or find another one that is more willing.
Just asking here, the vehicles that I have had in my bay with sooty pipes, I've added cetane boost and put in known good (high cetane) fuel, they've come back with clean pipes. Does that mean the good fuel "welded" the crack back up?
Style of driving and fuel quality are the major contributors to excessive soot. And no, I didn't clean the pipes, they cleaned themselves. Can a damaged DPF show in this way, sure, but there will be other indicators as well.
before I rushed in for a new DPF I would want to ensure there are no other causes. Leaking injectors, EGR issues.
Early on we could say it was a bad DPF...and it usually was, but I would not jump to that conclusion so fast now that it has been around for 3+ years.
Senix - I hear what you are saying but even if the truck had a leaky injector or EGT issues, the DPF should still catch the resulting soot particulates and the regen would occur make more frequently and burn of the excessive fuel. If you have soot build up down stream of the DPF filter and even more so, if you can visibly see smoke coming out of your pipe, the DPF is faulty.
The underlying problem (i.e. Leaky injector, EGT issues, etc...) could be what caused the DPF filter to fail so it would need to be addressed as well as the DPF replacement.
Style of driving and fuel quality are the major contributors to excessive soot. And no, I didn't clean the pipes, they cleaned themselves. Can a damaged DPF show in this way, sure, but there will be other indicators as well.
The tailpipes can't clean themselves. They don't get nearly hot enough to burn away the soot that far away from the DPF.
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