My Maxxforce Dt466 has been a workhorse for three years, but recently I’ve encountered persistent regeneration and fuel dilution problems. Every five months, the EGR intake and exhaust would clog, requiring cleaning and baking. To resolve this, I installed new Tamrax tube-style coolers, cleaned all visible carbon buildup, and replaced the intake heater. Initially, I experienced a slight power loss and frequent regenerations (5-6 times daily) immediately following the installation. The next day, regenerations continued in the morning but ceased in the afternoon.
Suspecting a dirty DPF filter, I swapped it with a cleaned one. This restored power, but regenerations returned, occurring 2-3 times per day. I then noticed a 3/4-1 inch rise in oil level, indicating fuel dilution due to the frequent regenerations. Concerned, I replaced the intake-side EGR cooler with the original fin-style cooler (cleaned and baked), installed a used EGR valve (awaiting a new one), and changed the exhaust back pressure sensor. The truck now runs powerfully, but regenerations persist, starting after about 10 minutes of driving and lasting for 15 minutes.
With no clear solution, I contacted the dealership, who informed me there would be a 4-5 day wait for diagnostics. Changing the oil every few days due to fuel contamination is unsustainable at $300 per oil change in Canada. Has anyone experienced similar issues with their MaxxForce DT466 and found a solution? Any guidance or suggestions would be greatly appreciated.
