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Discussion Starter #1 (Edited)
Have a diesel exhaust smell making it's way into the cab. If you haven't seen any of my previous posts, I have had bad luck with the turbo and other things. Truck was in the shop over a month as they couldn't figure it out. Ever since they replaced my turbo, the dealer has not been able to get the flange sealed well behind the turbo. Found the leak in my first picture.

Checked everything out and may have found a bigger problem. The accordion pipe at the back of the dpf appears to be deteriorating badly. See second and third pics. The wire mesh is gone in this area as well. There is a hole in the accordion portion. Anyone ever seen this? I am making an appointment with the dealer but I would imagine the dpf needs to be replaced. It almost looks like def fluid is running back a bit and corroding this section. Not sure if it can do that. We will see what the dealer says.

Edit....cant seem to upload pics. Will try later
 

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@fharrison - how many miles on your odometer now?

Definitely looks like something is leaking in that area and being burned off, based on all of the rust and that much of the mesh screen already gone = doesn't look right for a truck < 2 years old...
 

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Discussion Starter #5
@fharrison - how many miles on your odometer now?

Definitely looks like something is leaking in that area and being burned off, based on all of the rust and that much of the mesh screen already gone = doesn't look right for a truck < 2 years old...
27,800 miles. Almost 1 year old. There is a hole in the outer fold of the accordion section. It looks like it is corroding from the inside. I wonder if that area was heated badly during a regen.

My only other thought is that the def injection is about 8" behind this area and some of the fluid is running back into this area. Could it cause this kind of corrosion? Pipe appears to be angled back to this point slightly.
 

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OK, you're putting some pretty good annual mileage on your truck, which I think you have mentioned before...

Can I ask how your DEF consumption is?

From the pics, I am guessing your latter suspicion is what I would guess = small hole in the accordion pipe where DEF is weeping thru and soaking that mesh jacket.

The flow of liquid combined with a constant heat/cool cycle of the exhaust system from driving has created the perfect environment for rust.

The entire exhaust system gets hot according to the EGTs in FORScan, so me thinks you have pretty good science fair project going on here w/title: Environment to create accelerated rust
 

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Discussion Starter #7
OK, you're putting some pretty good annual mileage on your truck, which I think you have mentioned before...

Can I ask how your DEF consumption is?

From the pics, I am guessing your latter suspicion is what I would guess = small hole in the accordion pipe where DEF is weeping thru and soaking that mesh jacket.

The flow of liquid combined with a constant heat/cool cycle of the exhaust system from driving has created the perfect environment for rust.

The entire exhaust system gets hot according to the EGTs in FORScan, so me thinks you have pretty good science fair project going on here w/title: Environment to create accelerated rust
My def usage has been very good when not towing. Close to 8,000 miles to a tank when not towing. Towing sucks the def. Maybe 900 miles to a tank.

Dealer appt on Wednesday. I would imagine a new dpf is needed as it's all one piece.
 

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@fharrison - what did the dealer have to say? Did he order a new DPF for you?
 

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Discussion Starter #10
Just heard back from dealer. They are replacing the dpf assembly. It appears that it must have heated that rear portion of pipe to the point of oxidizing.

If anyone is crawling around under their truck, I would just take a look at the accordion section behind the dpf. I am curious if this has happened to anyone else or if my problem was caused by the bad turbo.
 

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@fharrison - good to hear they are replacing the entire DPF assembly. I hope this is covered by 36K bumper-to-bumper warranty and no cost to you?
 

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@fharrison report back on your DEF usage once you get some miles on the replaced DPF assembly. 900 miles on a tank of DEF while towing seems very extreme compared to my towing experience. What kind of load/weight have you been towing?
 

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Discussion Starter #14
Well, I have some bad luck. I just got a CEL pop up. Code is P20EE which is related to the SCR catalyst. Going back in Monday. From what I have read, sounds like a new SCR is in order. I have also noticed the truck has reduced power and is using more def than usual. I will report back after I know more. A delete is looking like a near future purchase.
 

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@fharrison - sounds like this problem is working its way thru the entire emissions system. Thanks for reporting in and please let us know how you make out...
 

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Well, I have some bad luck. I just got a CEL pop up. Code is P20EE which is related to the SCR catalyst. Going back in Monday. From what I have read, sounds like a new SCR is in order. I have also noticed the truck has reduced power and is using more def than usual. I will report back after I know more. A delete is looking like a near future purchase.

@fharrison, I had a fun experience while I was in Albuquerque. Miles from home and headed further west to see the Big Ditch (Grand Canyon) and got an email that my truck had set a code. Didn’t realize it. Took it to local dealer and it was gonna be two days before they could get to it. He kind of asked if I wanted him to clear the code. After thinking about a millisecond, I said clear it. The code was P208E, the DEF pump missed a squirt. Hasn’t come back. I agree, can’t wait for a delete to come out. I don’t mind playing the game now but if it gets unreliable, it’s gone.
 

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Once I felt it was inevitable that our emissions system on these 3.0 powerstrokes were going to be unreliable and a future headache, I had it deleted. Runs perfect and no worries now while travelling.
 

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Once I felt it was inevitable that our emissions system on these 3.0 powerstrokes were going to be unreliable and a future headache, I had it deleted. Runs perfect and no worries now while travelling.
Can you give some additional details on your delete. I am thinking of doing this to mine. Bought the truck new July 3rd and have just over 21K miles today....its out of warranty soon anyways haha
 

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Discussion Starter #19
Well, I have some bad luck. I just got a CEL pop up. Code is P20EE which is related to the SCR catalyst. Going back in Monday. From what I have read, sounds like a new SCR is in order. I have also noticed the truck has reduced power and is using more def than usual. I will report back after I know more. A delete is looking like a near future purchase.
Truck went in this morning. Waited to hear what they found. Apparently there is a tsb for a reprogram for the issue. Running well now.
 

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Truck went in this morning. Waited to hear what they found. Apparently there is a tsb for a reprogram for the issue. Running well now.
I’ve heard that my P208E has been issued a TSB so I’m thinking about talking to my dealership to see if they suggest a re-program. Thanks for the update.
 
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