Remove and replacing a Doc/Dpf - Ford Powerstroke Diesel Forum
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Old 11-28-2011, 07:26 PM
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Remove and replacing a Doc/Dpf

I am planning on replacing my existing Doc/Dpf with gutted units. I'm going to keep the OEM muffler and tailpipe on the truck. Does the tailpipe and muffler have to be removed in order to replace the Doc/Dpf or is there enough room to slide them out and the gutted Doc/Dpf back in?

I was able to break loose the oxygen and temp sensors without destroying them. I plan on installing them in the gutted Doc/Dpf so i don't have to worry about taping up the sensor connectors. Will the sensors be damaged if i leave them in the gutted Doc/Dpf? I want the ability to turn everything back to stock for warranty work. And yes, I have a mini max tuner.
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Old 11-28-2011, 11:12 PM
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Yes you can, you might what to put some penetration oil on the joint just after the DPF, break it loose and take out the DPF, you have plenty of room, may want to use a strap to pull the back part of the exhaust aft after you break it loose to get it out of your way.
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Old 11-29-2011, 06:05 AM
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From what I hear, one of the easier ways is the following.
  • Put something under the pipe to support it.
  • Loosen all attachment bolts from the rear of the pipe and remove from the front.
  • Disconnect all the sensors and move out of the way to avoid damaging. May want to spray these with something as well as cbenn suggested above.
  • Using a ratchet strap at the rear, separate the exhaust end from the DPF and leave in place to accept new pipe.
  • Should be able to remove from under the truck at this point.
This is one of the methods I've heard which makes it easier.
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Old 11-29-2011, 06:11 AM
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I wouldn't mess with trying to remove the sensors until you have everything out from under the truck. don't be surprised if they don't want to come out. If they don't, I would just weld up the holes in the gutted system.

everything will come out and go back in without removing the dpf-back system. you can use a strap to hold it out of your way, or you can just push it out of your way with your arm.

unbolt the front two hangers from the frame rail! don't try to slide the rubber hangers off! LOL
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Old 11-29-2011, 06:58 AM
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can be done....but the sensor that is the farthest back usually will not come out, i would leave it with the DPF...break it apart at the front of the muffler, i have taken out a few,and that is where i split it plenty of room to them throw in a gutted unit and reattach....... how much for a gutted filter and cat?

ps i always spray the crap out of everything first ,and while im removing.. a large dead blow, plastic hammer, works well to back the pipe out of the muffler....
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Old 11-29-2011, 07:37 AM
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my right boot = dead blow hammer
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Old 11-29-2011, 07:43 PM
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I picked up a used Doc/Dpf with a 4" tailpipe and 5" chrome tip for $200 and then spent another $100 on a rotary hammer. Back to my earlier question, will the oxygen sensor be damaged if i put it in the gutted Doc/Dpf?
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Old 11-30-2011, 06:07 AM
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Quote:
Originally Posted by INJEKTER1 View Post
can be done....but the sensor that is the farthest back usually will not come out, i would leave it with the DPF...break it apart at the front of the muffler, i have taken out a few,and that is where i split it plenty of room to them throw in a gutted unit and reattach....... how much for a gutted filter and cat?

ps i always spray the crap out of everything first ,and while im removing.. a large dead blow, plastic hammer, works well to back the pipe out of the muffler....
Yeah, wasn't quite sure on the order regarding the sensors. Figured they could get damaged or pulled wrong if you dropped the pipe too low without disconnecting them first.
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