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The dealership is telling me that my DPF is cracked, and the sensors are melted??? I've been reading that the overhead tells you when the engine goes into regen.

I have 23k on it and a couple of weeks ago I took it in for engine light. Dealer reflashed now I get more info lights at start up than before. Also for the first time I got a ding and DPF 100% refer to owners manual.

I drove for 3 hours at hwy speeds getting to my destination after the warning. Never said regen, just stayed at 100% then lost 1/2 power started bucking and died. I think the truck has never done a regen and clogged the DPF which made it hot enough to melt the sensors, and crack the DPF. Anyone else have similar problems or thoughts? I had a similar experience with my 08 MegaCab.

I have 5000 Km on it and during the last couple of weeks before the incident, the overhead told me the DPF was 80% full, then 90% and I thought that since I was driving at highway speeds, it went into regen (but it didn't say 'regen' or anything) because it then said 70% full. On the next trip, similar readings on the overhead appeared. Then, on the return trip, the overhead said Catalyst Full, Service Required. So, I took it to the Dodge dealer and told them what it said, and they booked an appointment for getting it looked at in a week-and-a-half.

I told them, it should be looked at right away, but they said they couldn't do that right then. I drove about 2 miles and it quit. I was in the way, so I got it started again and slowly drove off the road (it would barely run and I could only get the RPMs up to 1000). The Dodge dealer finally got all the parts in yesterday (it took over a week) and they put them on and they are doing some more tests before I, hopefully, get it back later today. My feeling is that the regen never did happen. Has anyone thought of taking the DPF and Catalytic Converter off, pounding out what is inside and putting the empty shells back on? We used to do that with the catalytic converters along time ago on gas vehicles so we could burn leaded gas.

What do you think will happen? I would probably put an EGR plate on, also.

I had a similar experience with my 08 MegaCab. I have 5000 Km on it and during the last couple of weeks before the incident, the overhead told me the DPF was 80% full, then 90% and I thought that since I was driving at highway speeds, it went into regen (but it didn't say 'regen' or anything) because it then said 70% full. On the next trip, similar readings on the overhead appeared. Then, on the return trip, the overhead said Catalyst Full, Service Required.

So, I took it to the Dodge dealer and told them what it said, and they booked an appointment for getting it looked at in a week-and-a-half. I told them, it should be looked at right away, but they said they couldn't do that right then. I drove about 2 miles and it quit. I was in the way, so I got it started again and slowly drove off the road (it would barely run and I could only get the RPMs up to 1000). The Dodge dealer finally got all the parts in yesterday (it took over a week) and they put them on and they are doing some more tests before I, hopefully, get it back later today. My feeling is that the regen never did happen.

Has anyone thought of taking the DPF and Catalytic Converter off, pounding out what is inside and putting the empty shells back on? We used to do that with the catalytic converters along time ago on gas vehicles so we could burn leaded gas. What do you think will happen? I would probably put an EGR plate on, also.I would strongly discourage knocking out the DPF like people do with Cats. It will cause the truck to go into limp mode and DPF are very exspensive to replace. I recently did a 2000 mile trip and used cruise all the way and my truck did regen.

I averaged between 70-80 mph Matter of fact it did most of them during the first 1000 miles of a 2000 mile round trip. I was empty on the trip out. The return 1000 mile trip (with 9K lbs) did not result in many successful regens. I could watch the pyro temps go up (edge insight) then drop down. I did notice that sometimes the temps would climb for a short time then drop off and the sucessful regens counter would not get incremented.