Ford Ranger DPF Problems: Symptoms, Costs and What to Do

The diesel particulate filter, or DPF, is one of the most common sources of trouble on Ford Rangers. See our full guide to Ford Ranger common problems. It is designed to trap harmful soot particles from the exhaust, but when it fails, the consequences range from annoying warning lights to a truck that will barely move. If you own a Ford Ranger and suspect DPF problems, this guide covers everything you need to know: what goes wrong, how much it costs to fix, and when it makes more financial sense to sell rather than repair.

What Does the DPF Do?

Every diesel Ford Ranger sold in the UK since 2006 has a DPF fitted as standard. The filter sits in the exhaust system and captures soot particles produced during combustion. Over time, the filter fills up and needs to clean itself through a process called regeneration, where the trapped soot is burned off at high temperatures.

When regeneration works properly, you will never notice it happening. The engine management system raises the exhaust temperature, the soot burns away, and the filter is ready to capture more. Problems start when this regeneration process fails repeatedly, allowing the filter to become blocked.

Common DPF Problems in Ford Rangers

Regeneration Failure

This is the most widespread DPF issue. The truck attempts to regenerate but cannot complete the process, usually because journeys are too short or speeds too low. The engine needs sustained motorway driving at consistent revs to generate enough heat. Rangers used primarily for short urban trips or stop-start site work are particularly vulnerable.

DPF Clogging

When multiple regeneration attempts fail, soot builds up to a level where passive regeneration can no longer clear it. At this stage, the filter becomes partially or fully blocked, restricting exhaust flow and causing noticeable performance problems. If left long enough, the blockage can become so severe that even a forced regeneration at a garage will not clear it.

Differential Pressure Sensor Faults

The DPF system relies on pressure sensors to monitor how blocked the filter is. These sensors can fail or give inaccurate readings, causing the system to either skip regeneration when it is needed or attempt it when it is not. Faulty sensors are a common misdiagnosis situation, where the sensor is replaced but the underlying blockage remains.

DPF Temperature Sensor Issues

Temperature sensors monitor the exhaust gas temperature before and after the DPF. When these fail, the engine management system cannot properly control regeneration. This can result in incomplete burns, excessive fuel use during regeneration attempts, or the system refusing to regenerate at all.

Warning Signs of DPF Problems

If your Ford Ranger has DPF trouble, you are likely to notice one or more of the following:

• DPF warning light on the dashboard – This is the most obvious sign. It may appear as a filter symbol or as part of the engine management light.
• Limp mode – The engine restricts power output to protect itself. You will notice a significant drop in acceleration and a maximum speed well below normal.
• Reduced engine performance – Even before limp mode kicks in, a partially blocked DPF causes sluggish acceleration and a general feeling that the engine is struggling.
• Excessive exhaust smoke – Black or dark grey smoke, particularly under acceleration, can indicate a DPF that is not filtering properly or is attempting regeneration.
• Increased fuel consumption – Failed regeneration attempts use extra fuel. If your Ranger is suddenly drinking diesel, the DPF system may be repeatedly trying and failing to clean itself.
• Strong exhaust smell – A pungent, acrid smell from the exhaust can indicate incomplete regeneration or a DPF that is no longer functioning correctly.

Which Ford Ranger Models Are Most Affected?

2.2 TDCi (2011-2018)

The 2.2-litre engine fitted to the T6 Ranger is probably the most common engine to suffer DPF issues in the UK. It was fitted to a huge number of Rangers and the lower-powered variants were often used for shorter journeys and site work, which is the worst possible use case for DPF health.

3.2 TDCi (2011-2018)

The 3.2-litre five-cylinder is slightly less prone to DPF clogging because owners tend to use these trucks for towing and longer journeys, but it is far from immune. High-mileage examples can develop DPF issues once the filter has accumulated significant ash that cannot be burned off through regeneration.

2.0 EcoBlue (2019 onwards)

The newer 2.0-litre EcoBlue engine, available in single and bi-turbo configurations, has more sophisticated emissions equipment including a DPF and a selective catalytic reduction system. While the regeneration system is more advanced, the additional complexity means more potential points of failure. Early reports suggest the bi-turbo models are slightly more reliable in this regard, likely because they tend to be higher-spec trucks driven at higher speeds.

DPF Repair and Replacement Costs

The cost of dealing with a DPF problem varies enormously depending on how far the issue has progressed:

• Forced regeneration at a garage: £100 to £200. A technician connects diagnostic equipment and forces the engine to perform a regeneration cycle. This only works if the blockage is moderate.
• Professional DPF cleaning: £300 to £500. The filter is removed and cleaned using specialist equipment. This can restore a heavily blocked filter to near-new condition, but it does not work if the filter is physically damaged.
• Aftermarket DPF replacement: £800 to £1,500 fitted. A pattern part that does the job but may not last as long as the original. Quality varies significantly between manufacturers.
• Genuine Ford DPF replacement: £1,800 to £2,500 fitted. The factory part with full warranty coverage. This is the most expensive option but generally offers the best long-term reliability.

Bear in mind that if the DPF has failed due to an underlying problem, such as faulty injectors or a turbo issue, those faults will need addressing too. The total repair bill can escalate quickly.

How to Prevent DPF Problems

Prevention is always cheaper than repair. Here are the most effective ways to keep your Ranger DPF healthy:

• Drive on the motorway regularly. At least one sustained run of 20 to 30 minutes at 50mph or above each week gives the DPF system the best chance of completing regeneration.
• Use the correct oil specification. Ford Rangers require low-ash oil that is compatible with DPF systems. Using the wrong oil accelerates filter clogging. Check your handbook for the correct spec.
• Avoid lots of short trips. Repeated cold starts and short journeys are the single biggest cause of DPF problems. If your Ranger is used exclusively for short trips, DPF issues are almost inevitable.
• Do not ignore warning lights. If the DPF light comes on, take the truck for a motorway run as soon as possible. Ignoring it allows the blockage to worsen, and what could have been cleared with a drive ends up requiring professional intervention.
• Keep up with servicing. A well-maintained engine produces less soot. Worn injectors, failing glow plugs, and poor fuel quality all increase soot production and DPF loading.

When Does Selling Make More Sense Than Repair?

There is a point where throwing more money at DPF repairs stops making financial sense. Consider selling your Ford Ranger rather than repairing if:

• The DPF has failed more than once and you suspect an underlying cause that is expensive to diagnose.
• The repair bill approaches or exceeds £2,000 and the truck has other age-related issues.
• Your driving pattern means the DPF will likely fail again after repair because you cannot do regular long runs.
• The truck is out of warranty and approaching other significant maintenance milestones.

At RangerBuyer, we purchase Ford Rangers with DPF problems every week. We understand these faults, we factor them into our valuations, and we do not use them to lowball you. If your Ranger has a DPF issue, get a free, no-obligation quote and find out what it is worth today.

Frequently Asked Questions

Can I drive my Ford Ranger with the DPF light on?

You can drive short distances, but you should not ignore it. The light means the filter needs regeneration. Take the truck for a sustained motorway drive as soon as possible. If the light starts flashing or limp mode activates, stop driving and seek professional help. Continuing to drive with a severely blocked DPF can cause damage to the turbo and engine.

Is it legal to remove the DPF from a Ford Ranger?

No. Removing or tampering with a DPF is illegal in the UK. It will cause an automatic MOT failure and can result in a fine of up to £1,000 for a car or £2,500 for a commercial vehicle. It also invalidates your insurance. Despite what some garages may suggest, DPF removal is not a legitimate solution.

How long does a Ford Ranger DPF last?

Under ideal conditions, a Ford Ranger DPF should last 100,000 to 150,000 miles. However, driving patterns have a huge impact. Rangers used primarily for short trips in urban areas may experience problems as early as 40,000 to 60,000 miles. Regular motorway driving and correct maintenance are the best ways to maximise DPF lifespan.