Step-by-Step Guide for 5.9L Cummins DPF Delete Installation

1. Why Choose a 5.9L Cummins DPF Delete?

The Diesel Particulate Filter (DPF) is designed to reduce emissions but often restricts engine performance and efficiency. Removing the DPF from your 5.9L Cummins engine can provide several benefits:

· Increased Power & Torque – Reducing exhaust backpressure allows the turbo to spool faster, leading to improved acceleration and towing capacity.

· Enhanced Fuel Efficiency – Less restriction in the exhaust system means better airflow, resulting in improved miles per gallon (MPG).

· Lower Exhaust Temperatures – A DPF can cause excessive heat buildup, and removing it helps keep exhaust gas temperatures (EGT) in check.

· Reduced Maintenance Costs – Avoid costly DPF cleaning and replacement while eliminating the risk of clogging issues.

Important Note: DPF removal is illegal for on-road use in many regions, including the U.S. and Canada. However, some areas allow DPF delete for off-road or competition use. Always check local regulations before proceeding.

2. Preparation Before Installation

Before proceeding with the installation, ensure you have the necessary tools and components ready.

Required Tools:

· Socket set and wrenches

· Flathead screwdriver

· Exhaust cutter, reciprocating saw, or hacksaw

· WD-40 or Loosen-All for hanger lubrication

· MIG welder (optional for added security)

Required Components:

· DPF Delete kit (including turbo-back piping, clamps, and hanger brackets)

· Factory turbo V-band clamp (from the stock system)

· Replacement muffler pipe (if applicable)

Installation Environment:

· Work on a flat surface with enough clearance.

· Allow the exhaust system to cool before starting.

· Use proper safety gear, including gloves and eye protection.

3. Step-by-Step 5.9L Cummins DPF Delete Installation

Step 1: Remove the Factory DPF System

1. Start at the turbo and remove the band clamp securing the downpipe.

2. Loosen the bolt enough to unlatch the clamp, then pry the clamp away from the flange at three different points using a flathead screwdriver.

3. Remove the clamp but keep it for reuse with the new system.

Step 2: Cut the Exhaust in Two Locations

1. First, cut the downpipe next to the transmission.

2. Second, cut the exhaust in front of the muffler.

3. Spray the hangers with WD-40 or Loosen-All to ease removal.

4. Pry the hangers from the rubber mounts and remove the factory exhaust system.

5. Use a saw or hacksaw for precise cutting.

Step 3: Install the New Exhaust Piping

1. Place clamps on all connection points before installing the new pipes and mufflers.

2. Install pipe #2031 using the factory turbo band clamp. Snug the clamp to hold the pipe in place while keeping it adjustable.

3. Ensure the hanger rod is inserted into the designated mounting location.

4. Align all pipes properly before tightening to prevent leaks or fitment issues.

Step 4: Install the Mid-Pipe and Tailpipe

1. Temporarily hang the muffler replacement pipe in the factory rubber hangers.

2. Measure the distance from the rear of pipe #2031 to the front connection of the muffler. This will determine the required cut length for pipe #58936.

3. For longer wheelbases, use part #9102 as needed.

4. Make sure to allow approximately 5 inches for tubing connections and always cut from the non-reduced end of the pipe.

5. Install pipe #58936, ensuring clamps are in place before securing it.

6. Connect pipe #20356 to the rear connection of the muffler replacement pipe.

7. Install the tailpipe #20357, securing the hanger from inside the frame using the factory hole.

Step 5: Adjust & Secure the Exhaust System

1. Snug all clamps to hold the pipes in place while keeping them slightly adjustable for final positioning.

2. Check for proper clearance around brake lines, e-brake cables, and the axle vent tube.

3. Verify that the tailpipe exits level with the truck body.

4. Start at pipe #2031 and tighten the turbo band clamp first.

5. Continue securing clamps from the front to the rear of the system.

6. For added security, apply MIG welds to clamp connections, but DO NOT weld the clamps themselves.

7. Double-check clearance with suspension movement to prevent rubbing issues over time.

4. Post-Installation Benefits & Optimization

After successfully installing the DPF delete system, you can expect:

· Better throttle response and reduced turbo lag – The reduced restriction allows quicker turbo spool.

· Improved fuel economy – Many drivers report an MPG increase due to reduced backpressure.

· Extended engine longevity – Lower exhaust temperatures help prevent excessive wear on engine components.

To optimize performance further, an ECU tune is highly recommended. Use software like EFI Live or HP Tuners to adjust engine parameters, prevent error codes, and enhance power delivery.

5. Troubleshooting Common Issues

Check Engine Light Issues

· If the ECU is not tuned properly, the check engine light may turn on. Verify that the DPF delete tune has been successfully uploaded.

Exhaust Leaks

· Check all clamps and connection points for leaks.

· Retighten any loose clamps and ensure pipes are properly aligned.

Excessive Smoke

· Some increased smoke is normal after DPF removal, but excessive smoke may indicate improper tuning or a fuel system issue.

6. Frequently Asked Questions (FAQs)

Will DPF Delete void my truck’s warranty?

Yes, modifying the exhaust system can void parts of your vehicle’s factory warranty. Check with your dealer before proceeding.

Do I need to recalibrate the ECU after deleting the DPF?

Yes, an ECU tune is necessary to prevent error codes and optimize engine performance.

Is DPF Delete legal?

DPF removal is illegal for on-road use in many regions, including the U.S. and Canada. However, it may be allowed for off-road or competition use. Always check local emissions laws before making modifications.

Conclusion

The 5.9L Cummins DPF Delete is a highly effective modification for improving performance, fuel economy, and long-term reliability. By following the correct installation steps, ensuring proper ECU tuning, and troubleshooting potential issues, you can maximize the benefits of your upgraded exhaust system. However, always be aware of legal implications before making any modifications to your vehicle.

If you're ready to enhance your truck’s performance, ensure you have the right tools, follow the steps carefully, and enjoy the benefits of a freer-flowing exhaust system!