How can I get rid of my dpf on my 07.5

[BMemmott]

That is awesome!!! Is the check engine light on? I need this set-up!!!! GREAT JOB!

 

[Doughboy21kd]

Boy once people hear about this, this is gonna be a VERY popular thread... :-laf:-laf



THANKS ALOT for the pics and info... . Keep us posted on how it does... Did sound change, mileage change, codes, etc, etc... .

 

[courierdog]

Thanks and Keep the info and pictures coming

 

[Wolfy]

Mr. Wolfy

I would have addressed this the same if you was a moderator here or not really. It always best if we all can work together and through things like this. So after the fact, it was the least I could do by just removing all the stuff so offensive...



Guys I will make a few posts here of PIC's with what I have working right now. You do need to understand I just got the new "AU" flash and not at all sure how this will affect my truck with it being so different. By the end of this next week I should have those questions answered also.

Hi Jeb,



I am very impressed with your work, and the level of knowledge that is apparent in your comments. Good camera work, too.



As someone else posted, this thread is going to draw a large audience, and you will certainly have a group of attentive fans waiting for each report.



Do you mind telling us what your background is, regarding work experience, etc. , that has given you such a working knowledge of this sort of project?



I would also like to ask if you can tell us something about the purpose of the new "AU" flash that you mention?



Thanks,

 

[courierdog]

Yes the latest info on the AU flash would be very much appreciated.
I can find no information about it. My system is currently going into Active Regeneration for no appearant reason regardless of speed (town or highway)
In addition the EGR valve has a whole raft of other issues.
I will not fault my dealership as they are working on the issue, however, they have their hands tied by DC and Cummins; who do not know how to cure the problem or have their hands tied by some other regulation.
I am convinced the ECM could turn off all the defective sensors and the truck would run just fine while they worked out the problem. The additional fuel used in the over zealous Active Regeneration cycle is causing the engine to run high EGT (1100 - 1300) about 70 to 80 % of the time the boost is running between 2. 5 - 7. 5 lbs during the process.
The fuel efficiency goes from a high of 26. 54 MPG to a low of 12. 3 MPG while running at 60 MPH at a sustained RPM of 1600. 6 speed auto with 3. 73 rear end.
I would very much appreciate any input.
My background is 42 years as an Electronic Engineer, retired and for my hobby I operate as a courier/hot shot - owner/operator running about 6000 miles per month.
Thanks for your daring input.

 

[2Rowdy]

Mine is basically the same as courierdog except I don't think my overhead even reads that high on mileage as I've never seen it. certainly not hand calc. I get about 13. 5 to 15. 2 depending on driving and towing. Maybe less towing I have not towed a full tank from full to empty.

 

[Jeb_H]

Guys,



The new AU flash was suppose to deal with the cooler by-pass valve standing open or at least the ECU thinks so. Mine and one other in the area here that this dealer works on. Only two this dealer has from what the tech told me.



There was suppose to be a few other small things addressed also, like help a little with fuel mileage and such.



Well this morning run was its first and the truck ran fine, but it maybe running in regen somewhat all the time as Courierdog mentioned his was. I will know more maybe tonight when I leave out again, but if I had to guess I would say its in regen, at least the very first stages of it.



Now this will be where it gets really tricky too, if my exhaust system lets the ECU think the filters are stopping up enough for a regen and its going into this all the time now as there is nothing for the regen to burn out, won't know for sure for a little while



Sure need some guages on this truck, but I keep holding out for the PMT system from Bullydog, but I am not going to be holding out much longer, and just get something else. To much time has already passed...



My work back ground, well I did pipeline construction and repair for more than a few years and all over the place. Plant work as well as over the well bore. So I know my way around plumbing stuff of all types and from small to really large, hot as well as really nasty cold also



I got out of that for the most part but not all together, and went to work for an Outboard motor company, some may know as OMC, they built Johnson and Evinrude outboard engines for boats, which I cut my teeth on those as a kid growing up on a lake in Texas. I had the lake right out the back door as a kid. So working on these motors is second nature for me...



OMC filed Chapter 11 on 12-22-00 and I went to work later on for the company that bought those motor lines and they had me working up north for a while and offered me a position at the Racine, WI. plant... It just never felt right and was not the right time for me to make a move like that I guess, as I refuzzed and came back home...



Right now I provide a hotshot service for a certain area around here, company I contract this route from is from the D/FW area. I usually run 2500 miles a week,at least that much and more some weeks. Keeps me busy to say the least.



My truck has never gotten the mileage I see being posted here either... I am not so sure about this new flash as I had my truck do a cough twice about 5 seconds apart on the way back this morning early. Not sure at all what that was about as it quite about as soon as it started and has not done so again.



Could have been poor fuel, but I doubt it really. If this was a two stroke outboard, it would be telling me the motor was way too lean when it done that and I would be fattening her up and quick too



Not knowing more about what they may have done with the timing on this latest map change, does have me asking if maybe the timing might be off??? I have just not ever had a diesel do something like this before, but it sure sounded lean and I felt a miss at the time this was all going on too...



Now changing the subject back to the topic at hand, I don't want to be blamed for hy-jacking the thread here LOL... One thing you guys do need to keep in mind here is that while my system has the truck running well up and until this morning, its not a straight pipe system per/say...



I do still have the OEM down pipe on so far as well as its got several rifling veins in strategic places that are acting somewhat restrictive. Nothing close to the stuff that was on this truck though LOL...



I am certain to have the software change needed to be able to run sure enough straight pipe setup will be best. But until that comes about, I had to see if I could fake the system out somewhat and get the DPF off the motor before it killed the turbo as well as the rest of this setup...



I also see a hugh thing with just how freakin' well the 6. 7 runs at 2250-2400... I sure would be curious to know just how well a truck like this with the 4. 10 gears would do. Sure seems to me to be the ticket, but with how wild mine has been from one day to the next through all this, who knows

 

[courierdog]

My consul reads very close to actual fuel usage. I am currently working at installing a Spinner II bypass filter to minimize the extreme soot contamination of the oil. The truck runs well with the exception that it is currently running very high EGT's 70 - 80 % of the time, with resulting poor fuel efficiency. Prior to the install of the guages I could only tell the truck was in Active Regen by the decrease in fuel efficiency. At the end of June on an extended trip according to the decrease in fuel efficiency it ran for 3 days in what is now documented as EGT of 1100 - 1300 degrees.
Yes the ECM does record all these events according to my Diesel Tech, also fortunatly the Service Manager is cooperative but I believe has his hands are tied by the system in what he can or cannot do.

 

[blacksheep4x4]

Nice work Jeb! Hopefully everything goes well in the next few weeks. Who would have thought that just putting in a little restriction in the new exhaust tubing would fool the computer.

 

[Jeb_H]

Blacksheep,



Yes all it was basically is a restriction as you mentioned, but by doing so with the rifling vein will help with keeping the soot and smoke plume all stirred and from settling quite so bad and go ahead and carry on out the tail pipe.



At least its been working quite well considering it does still have some restrictions and she doesn't go into the limp mode... Not sure what to expect just yet from the new AU flash and how it may or may not affect the exhaust system I have...



Really though if I need to add more restriction in one of the three stages or less as it very well could need some removed now if in fact its staying in regen. Should know more in the morning, coarse my mornings start at 11:00PM central time LOL...



I should be asleep right now and I ain't and have not been in well over 30 hours as of now... I would really love the time and stuff needed to mess around with stuff like this.



I feel I could get the dpf as well as the egr working, for sure with a little in put from the manufacture and a parts following as I would need a few things. As it is now, I am focused on removing all this stuff and re-routing things...



Been digging around in a few bone piles that I keep under close watch for goodies a person like myself might could use every so often.



Now for you guys that might like to mess with some of this rifling as I have, first things first. The metal that puts everything in a twist is what is more commonly called "flight" or "Flighting". Its used in all sorts of things such as augar bits and the like.



What I have here is just 3. 75" OD which allowed me to weld the three pieces of flat bar that is . 125"X1/2"wide.

This all together makes for a nice snug but slip fit into the four inch tubing. The small flatbar strips function as a way to keep each lead of the flighting from chattering in the tubing at certain harmonic RPM's and can chatter enough so and left unchecked will chew a hole right through anything.



You guys interested in doing this as time allows me I will get right on the spacing and the lengths I have now. I do want to make sure first though, that this new software reflash has not unbalanced this and a little more tweeking not needed just yet.



It may also be more easy for most of you to just wait for what will be better which will be the programmers to remove this for all offroad use and have a sure straight exhaust... This was just something for me to mess around with and in hopes of getting some answers to some of the hows, dos and don't of this new motor.



Most of the stuff I already had around the shop so its not cost me much but the time. Which my time is at a premium anymore with the amount of driving I do...



Anyway, I will help anyone I can with getting some of this to mess with if they so choose. Its just not a simple put in and play just yet since the new flash I need to find out whats-zup with everything on her under the hood. Right now I must get a few hours sleep... Laterz

 

[courierdog]

Jeb: just in case the Current post is deleted I copied all of your efforts and have saved them on a Word Document. I would appreciate any and all future information / Pictures you develop in the process. One thing, I for one, would rather keep the ugly duckling or at least the Physical External device(s) rather than run straight pipes which advertise the modification.
I would appreciate an email. Thanks

 

[JimB1]

Jeb H, Don't know a lot about your strategies for re-piping but I do know in post #60, that's some excellent 6011 or 6010 pipe flange stick welding.



For those of you practicing stick welding, it's not about smooth but rather uniform and even. Jeb H laid each ripple in, identicle puddle laped over identicle puddle laped over identicle puddle. Hang a picture of that over your welding machine.

 

[metwuk]

Ditto!!!

DITTO DITTO!!! :{

Jeb, lay it on us. Some People get offended really easy over others "opinions" and guess what? Oh well! You cant make everyone happy and that just how it is. If they are not interested in the thread they don't have to read it. No need for you to apologize IMO to overly sensitive people. Keep up the good work.

 

[Jeb_H]

CDog,



Dude I know what your wanting to do and I have done this with cats before and its not much to it really. Its all about gutting what the filters have inside and then run new straight pipe right straight through it and weld that all in place and have your flanges on the ends as is.



You really open up a mess of things if you leave the empty cans of the filters as a large cavity. It causes a bigger problem so its a lot better to just drift the tubing through them all of the same size you want to use and then just weld everything to look all normal.



Dude, the only problem I would see is you scrap the filter system by doing this unless you know where one is that has been tossed. I want to keep the OEM system handy for a later use when I go back to driving on all highway roads if you know what I mean LOL...



They have this system priced way out there in left field right now, as they also have the turbo for this motor as well. I was told 55-5600 dollars for the turbo and I have been also told if you can buy the DPF system if may be as much as 6000, either way a whole lot of $$$...



Now with what I am doing with the veins to simulate the differencial pressure across the traps with the sensors, they will slide in place, you don't have to weld them in or tack them. It allows for messing around as things change as with a new flash or the like...



After todays run all night and half the day so far, I am certain I can reduce some of the restrictions now and get the differencial pressure a little closer together now, and that is a good thing. We ever get the help with some software for the ECU so as to use a straight pipe setup, that will be the ticket for sure... I will be yanking the riflings out this week-end to see just how close I can get now The new AU flash does seem and act like it will surport this much better, unless I missed something in how the 6. 7 sure acts right now.



I still have the CEL but its the cooler by-pass valve issue still I figure as its been there since day one It in time will go also though as I am certain of it At least no safe mode or limp mode...



I am eye balling the down pipe at the moment, as the place to work off the less restrictions too. I will slide out one of the riflings out and run her for a smoke test and if she loves it as I think she will. I will install the rifling back in as its all so easy to do with how this all works.



Then I will remove the OEM down pipe and fab my on up without the small cat. I will add a small 1" or so lateral line for the slobber line that puts the plume from the top of the head right in the front of the turbo, adding it to the down pipe instead. There it can burn up and clean the air by fire



I want to tap the high pressure side of the filtered air going to the intercooler and take it to the EGR system starting right with the cooler by-pass valve. I just hate to think about all the exhaust gases running back through the intake as it is... That just seems low suck to me and just has to be hard on the valves and such...



I bet these 6. 7 motors that they have had prior to ours in the truck never was like that!!! Anyway, I have to go in small baby steps and keep this sucker where I can get this all done in steps on a weekend, that always is to short



So, how bout some more art to look at right now??? I have three new PIC's to share of the new straight and smoothed bore intake tube. Oh, yes it does flow better also...

#ad




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Now its not perfect just yet, but its better than what came on her. There will be a small adjustment made soon enough that will add an ever so slow counter clockwise twist to the incoming air. This will allow the turbo to feed off it even better as it rotates clockwise. It will allow the turbo to feed at will on all the fresh air she wants and all in the very near future

 

[courierdog]

That is an awsome Intake!
How have you managed to filter the input?
How have you managed to get this air intake to see the outside world for AIR?

 

[Jeb_H]

CD,



The intake tube you see here is nothing more than a transfer tube. Its the tube between the airbox, where the filter is and the turbo. There is really no big trick here dude with just the tube as its shown.



Its advantage over the OEM tube is that its all smooth on the inside and has the same size from one end to the other. Unlike the OEM with all the uneven size and kinks and bends in how they made it.

 

[KEpperly]

if you call this highjacking a thread. let it be done all the time. good work

 

[Jeb_H]

No new news to anything here yet, this week has ended to be one of the craziest on the route I run. So I just had no time to pull one of the rifling veins out of the exhaust system to see if what I think is going on to be true.



I will be changing the engine oil this week-end and I will yank one of the veins out and have a little run time to see just how things are without it since the AU flash...



I swear this thing sure looks and acts like its going in and of regen now. If that the case I will need to find the balanced spot with this new flash and that will be a good thing since I will be able to use less restriction from the veins...



I really want to build up the new down pipe and yank the OEM down pipe now and just get the last of that stuff off the motor. Just so many things and so little time

 

[JRader]

Jeb H,



I got to know, How loud is it with no DPF's and how awesone does it sound? PLEASE TELL. I'd be willing to pay you to make me the same pipe for me when you get it working right. This is the first truck I've ever owned that I can't make loud and its killin me

 

[Jeb_H]

JR,



Its not loud at all, but it does have some what a throaty sound right now. I have since added a 5" tail pipe from the axle back and that seems to have a really good sound affect to all this as well. I do think the loud part would be getting the last of the filter out of the system which is the down-pipe... Once I get where I can address this last part I will be into an area where the sound may be an issue for sure.



I am not so much for the loud as much as I am for a good performer. I hate this throttle response the 6. 7 has... Its as low suck as I have seen from anything other than maybe the 4 stroke stick edger I bought LOL...



Guys, on another note I have since removed all b ut one of the rifling viens I put in the system and I will need to get a little mileage on this before I know much.



I can tell you that the new AU-flash has done some wild stuff to mine for sure... So not at all sure just what to think about all this. Heck I am not at all sure with this AU flash that you may can run straight exhaust without anything in the tubing. Which would certainly be a lot better on the turbo and exhaust valves...



I certainly understand some of the real troubles the electronic guru's are facing getting the programmers as well as the exhaust systems for off road use all worked out with a reflash like this new AU having the affects it has on my truck...



We all can only hope someone will be able to work all the electronic parts out on these motors and get us all the off-road version available to those of us that want one... I am working on mine as much as time allows and that my tired body allows



I just want better fuel mileage and quicker throttle response from mine, as for the sound its a luxury I don't have to have really, but I figure its coming as a freebie from a system that gets all this system worked out.



So guys have any of you that have the new AU-flash tried running the exhaust system with a straight pipe yet??? I am not so sure you would have to much of an issue with this system and the AU-flash. Mine sure has done some really weird stuff this past week. No help on the fuel mileage that I have been able to see.



So anyone seen or tried anything new to add to the mix of all this??? I know my 6. 7 is running somewhat hotter now since this AU flash... My guage stays on the 200 degree mark for the most part and if I get in the throttle as to climb a slow grade increase or pass someone, it moves above the 200 mark.