Tackling Common DPF, DEF, and EGR Issues in Box Trucks: Prevention and Solutions - RK Truck Sales
Tackling Common DPF, DEF, and EGR Issues in Box Trucks: Prevention and Solutions

Tackling Common DPF, DEF, and EGR Issues in Box Trucks: Prevention and Solutions

April 26, 2023


Diesel Particulate Filter (DPF), Diesel Exhaust Fluid (DEF), and Exhaust Gas Recirculation (EGR) systems play crucial roles in reducing emissions and improving air quality. However, they can also cause headaches for fleet managers and truck owners due to the common issues they may experience. In this article, we’ll explore some common problems with DPF, DEF, and EGR systems in various box truck makes, the reasons behind these issues, and how to prevent and resolve them.

DPF Issues

DPF systems help to reduce particulate matter emissions by trapping soot particles and burning them off during a process called regeneration. However, issues can arise when:

Regeneration doesn’t occur frequently enough, causing the DPF to become clogged with soot.

The truck is mainly used for short trips or idling, preventing the exhaust system from reaching the required temperature for regeneration.

Prevention and Solutions:

Ensure that your truck is driven at highway speeds for an extended period to allow for passive regeneration.

Schedule regular maintenance checks to ensure that the DPF system is functioning correctly.

If the DPF becomes clogged, have it professionally cleaned or replaced as needed.

DEF Issues

DEF is an essential component of the Selective Catalytic Reduction (SCR) system, which reduces harmful NOx emissions. Common DEF issues include:

DEF contamination due to improper storage or handling.

DEF crystallization, which can clog the system and cause malfunctioning.

Prevention and Solutions:

Always use high-quality DEF from a reputable source and store it properly to avoid contamination.

Ensure that the DEF tank is filled with the correct amount of fluid.

If DEF-related issues arise, have the system inspected and cleaned by a professional technician.

EGR Issues

The EGR system helps reduce NOx emissions by recirculating a portion of the exhaust gas back into the engine’s intake. Common EGR issues include:

Carbon buildup in the EGR valve, causing it to stick open or closed.

Leaks or blockages in the EGR cooler, leading to overheating and engine damage.

Prevention and Solutions:

Schedule regular maintenance to clean the EGR valve and inspect the system for leaks and blockages.

Replace the EGR valve and cooler as needed to ensure optimal performance.


DPF, DEF, and EGR systems are essential for maintaining your box truck’s emissions compliance, but they can also present challenges. By understanding the common issues associated with these systems and implementing preventative measures, you can keep your truck running smoothly and efficiently.

At RK Truck Sales, we are dedicated to helping our customers maintain their trucks and prevent costly repairs. Our knowledgeable staff can guide you through the maintenance process and provide advice on how to address common DPF, DEF, and EGR issues. Contact us today to learn more about our truck inventory and how we can support you in keeping your fleet running at its best.

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