Ford Super Duty: How to Replace Catalytic Converter/Diesel Particular Filter

Is your "cleaning exhaust filter" light coming on much too often? Perhaps it is time to replace your catalytic converter or diesel particulate filter. We've got your step-by-step guide on how to get the job done.

By Brett Foote - July 9, 2015

This article applies to the Ford F-250 and F-350 Super Duty (2005-2014).

Whether it's just time to replace your catalytic converter due to mileage, or you need to replace your diesel particulate filter, tinkering with your F-250's exhaust isn't as complicated as you may think. Ford recommends that your DPF be removed and cleaned around the 120,000 mile mark and replaced at 250,000 miles, depending on use. Catalytic converters typically last the life of the vehicle, but replacing them can become a reality in diesel trucks that rack up the miles. If you need to replace either, you can save a ton of money by doing the job on your own. Keep reading to see how easy it can be with our step-by-step guide.

Materials Needed

  • Wrench or socket set (sizes vary by model)
  • Floor jack and jack stands

Step 1 - Lift up the truck to gain access to the DPF/catalytic converter

Use a floor jack to lift the front of the truck up and place it on jackstands. Locate the DPF and catalytic converter assembly, which is located forward of the muffler and behind the engine exhaust manifolds. Remove the sensors which are connected to the assembly carefully using a wrench. Take care not to damage the sensors, or they will need to be replaced as well.

Figure 1: A typical exhaust system layout. "View B" is where the Diesel Particular Filter/Catalytic Convetor in a Super Duty would be located.

Step 2 - Remove the DPF and catalytic convertor

Start by removing the 4" band clamp that is located towards the back of the DPF with a socket wrench. Loosen both bolts on the flange from the stock downpipe. Detach the exhaust hangers from the factory isolation mounts, taking care not to damage them. Carefully lower the assembly and slide it out from under the truck. At this point, you can remove and replace either the DPF or the catalytic converter, or simply clean the DPF if needed, by detaching them from one another.

Figure 2: A Super Duty exhaust system showing the various components.

Step 3 - Reinstall DPF and catalytic converter

Slide exhaust assembly up and into place underneath truck. Reattach exhaust hangers to the factory isolation mounts. Tighten the bolts on the flange from the stock downpipe and reattach the 4" band clamp located at the back of the DPF. Lower the vehicle and start, looking for any potential leaks or problems. Take for a test drive and ensure everything is operating properly, and verify there are no dash lights coming on.

Figure 3: A installed exhaust assembly.

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