6.7L Cummins Forum

All right men here is my story. Up until 1 month ago i was a proud 6.7L cummins owner. i have 47k miles on my truck and suddenly it has gone to heck in a hand basket. the truck is all stock exception being an S&B intake, and 305/75/17's for rubber. driving down the freeway 70 mph she blew out one heck of a cloud of black smoke and wouldnt get out of its own way. Literally. towed to dealer via flat bed wrecker, 4 days later and a new dpf and i was wheelin again seemingly fine. 1 week later same exact scenario, only this time the dealer replaced the egr valve. i should add that i replaced the fuel filter at my last oil change which was 2500 miles ago. and my normal driving consists of 42 miles each way all but 1.5 miles highway. truck again seemed to be fine after egr replaced for about 1 week then the same exact scenario again......big cloud, no power. my truck is an early 6.7 so i have no indicator to tell me the truck is in regen. i get a CEL each time for "egr circuit low" the truck is at the dealership now with the same symptoms (4 times in a month) they cant figure it out and have resorted to blaming the S&B intake????? they tell me it is sending numbers to the MAF sensor that are out of its parameters? Why no MAF CEL then was my question? they had no answer. We are currently at a stalemate it seems. Please folks, any advice or help/ similar experiences would be more than greatly appreciated! by the way as a side note, my truck never had an issue one until the recall reflash was performed at the dealer. may be totally unrelated but sure seems odd to me?

Ok, so what I would do is put it back to stock intake and run it. When and not if, but when it blows again, find a new dealer. Find one that actually has a diesel mechanic and not a gasser monkey reading error codes.

I would also install an Edge insight gauge and monitor regens. I think regens are not running at all and sensor is dead so it thinks it never has to regen.

I am starting to see a trend forming here with dealers that can not resolve things .... What a surprise !

What flash updates did they do ? Did you get a J35 update ? If so, are you running with the EGR disconnected ?

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I agree, they don't seem to have the Mechanics with the proper training at a lot of dealerships so the shotgun parts and grasp at straws.

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2007.5 Dodge Ram 3500 HD,QC, 6.7L Cummins, 6speed Auto, 4X4, Bighorn Edition.
Click for installs: Carr Steps PML Diff Cover Edge Juice with Attitude Volant Intake Hankook ATM RF10

Early 6.7L cummins are Junk from Cummins and Dodge. The Fix, get rid of the EGR, bypass the DPF?/Cut it off!!! and get a straight exhaust from cat back with a muffler. H&S tuners are great on mine thus far and you will not believe the change in power. Basically the DPF chokes the Diesel and the EGR is Putting Dirty/ unburned exhaust back into your engine. The EGR WILL NOT BE UNDER WARRANTY AFTER 50,000 MILES not 100,000 miles. Read your warranty manual for 6.7L engines, Also, the turbo, exhaust, injectors and fuel system warranty is under emission warranty not main engine like the 5.9. Dodge had to know there was going to be issues. Cummins will tell you ther is no fix, and that Dodge buys the engine from them WITHOUT WARRANTY! Call me and I can tell you more! (804) 314-5091. Adding the tuner will probably void your warranty, but a new injector from Dodge will run $1450.00 and no this is not a typo. 6X $1450 just for injectors. There was a major class action suit filed against Dodge this past January and they File bankruptcy in May of this year. There is still no fix thus far. I kept all of my items for my truck in case I need to put them back on, but until there is a fix, I am not taking the chance of a $2000 to $12000 repair on my tab.You can thank our Government and wonderful EPA for this one and Dodge for eluding the responsibility to the customer. The 2011 Dodge is really no better! Other than these issues, I still have mine and so far I am pleased with my FIX! It is like having the 5.9 original with kick!

hey men thanks for the input! Morbius i did get the j35 reflash and i am running with the egr active. Again i appreciate the help

Ok, so looking at the posts, here is what I have to say ...

Hillge,

Chill and drink a nice warm glass of milk ! This is not a forum like others, we are all here for solutions and making our trucks work as they should. Take what you read on the internet with a grain of salt. This is not a place to bash Dodge and/or Cummins.

Yes removing your entire smog system is a solution in some places, in others, it will lead to some very hefty fines that are just not worth it. Smog on a early 6.7 and late current, exactly the SAME ! Only change, ECU programming and one additional sensor on the 2010/2011 models (that is for those people that plug the EGR tube ....) Face it, diesel smog is here and it will stay, like it or not. Enough people here with age and history that can talk about PVC / EGR / CATS on cars, now a days, its a mute point.


bkdraftbn1,

I strongly recommend the Edge Insight gauge. If you search the forums about Edge Insight, you will find some great posts on it. Programmed right, it will show you alot of data about how your DPF and regen system is working or not working. What is the manufacture date of your truck (located on the driver's door) ? Its important to know that info. If memory serves correctly, early 6.7L ECU required other updates before installing the J35. Basically the ECU had to be brought up to date before appling J35. The sure sign of that is it would have taken many hours to do it, not an in/out deal.

The details (big or small) you can provide, the more help we can provide.

Cheers.

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thank you morbius, the j35 update took about 30 minutes at my local dealer, and the date of manufacture on my truck i am not currently sure of because the truck is still in the shop. i know the trucks in service date is april of 07. Sorry i dont have more info, one other thing i can tell you that may be of interest is the exhaust brake doesnt work when the truck is "acting up" I only know this because i run it all the time as my dealer told me running the exhaust brake would help????? I can also add that i put a code reader on the truck after this last episode and it said "egr circuit low"? Ever seen that? As of today the dealer is still blaming the S&B intake. They tell me they are going to put a stock intake on the truck tomorrow and "run some tests" and they will get back to me. I greatly appreciate the help and or advice. Anything you guys can share is a help!

30 minutes for the update means that prior updates where not loaded. It takes that much time for J35 by itself. A service date of 4/07 I think means early 6.7L ....

Exhaust brake acting up means soot blockage on the vane slots. Leaving it on all the time, does help a lot in keeping it moving. That solves several error codes for the turbo. Exhaust brake on and using it during regen I found cause the usage of more fuel usage to keep the DPF at the needed temp.

The dealer wanting to revert to stock intake, well that will not solve the problem cause the S&B intake does not flow that well to make the MAP sensor read false. But you have to let them test their own stupid way. I feel though that they will not figure it out.

The problem lies in the update they did. Its not compatible with an existing early version sensor. There have been ongoing sensor changes between the years to correct problems. If they went back to your original firmware and updated it in sequence till they got to J35 and read all the service notes, I think they will see a note or two about something a long these lines.

What is sad is that all was working well till this dealer did a code upgrade. If they can not see that in your records, well, time to find dealer that has experience (not many of them around).

Hope that helps. As you may have figured out, software programming and computer control systems is my line of work and deal with these same problems on a much larger scale ...

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Morbius i greatly appreciate the help and you are correct as of today (the trucks tenth day in the shop) they are now saying maybe its not the intake, maybe it does in fact have something to do with the reflash.

Sorry to hear your truck is still in the shop, that sucks ! Glad to hear that they are heading down the right track.

I can see it now .... The dealer is talking to corporate support level 1, corporate is talking to some engineer at level 2, the level 2 engineer is asking for assistance from the coders, they are saying RTFM, and somewhere in this mix, someone at corporate is talking to cummins support level 1 and so the cycle continues .... Hence the 10th day ....

Gotta love how this all works .....

Hang in there. Easiest and fastest fix for them and you is to replace the ECU and flash update it. It will already contain the various updates and only a couple updates to install. They can have your truck out in 1 business day. The old ECU can be blanked, reloaded and returned to spares.

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