Imagine an alternate universe where aftertreatment sensors can be removed with ease. No more galling, no more threads wreaked, no more skinned knuckles, no more swearing and throwing tools. While this might make a great episode of The Twilight Zone for gearheads, the reality is often the opposite. Sh!t happens. Bungs break.
So, what do you do if a sensor port (weld bung) gets damaged during a sensor replacement? In most cases, weld bungs are replaceable, saving you the cost of replacing the whole DPF/DOC/SCR. Weld bungs for diesel emissions systems cost around $25. Replacing the weld bung will also involve some time, effort, and expertise, but with a new DPF costing between $700 - & $5,000 or more, it’s often worth it.
Remember: Safety should always be the top priority when working on your vehicle's exhaust system. Wear appropriate protective gear, including gloves, safety glasses, and a respirator.
Disclaimer: Replacing a DPF weld bung is a complex task that requires specialized tools and skills. If you're not experienced or confident in your abilities, it's highly recommended you leave it to the professionals or, at the very least, seek professional guidance and supervision.
Preparation and Tool Selection
- Choose the right bung: Ensure the replacement bung matches the original in terms of size, thread pitch, and material. Stainless steel is preferred due to its corrosion resistance.
- Tools and Materials Needed:
- Replacement DPF weld bung
- Welder (MIG or TIG)
- Grinder, Hole saw, or cutting tool
- Wire brush
- Safety gear (gloves, goggles, etc.)
- Additional tools: You may also need a drill, taps, dies, extractors, and finally, thread anti-seize is essential.
Removal of the Broken Bung
- Assess the damage: Determine the extent of the damage to the bung and surrounding area.
- Drilling and extraction: If the bung is broken off flush, carefully drill a hole in the center and use an extractor to remove the remaining pieces.
Bung Removal - Pro-Tip:
Often it’s easier to remove the broken bung from the filter using a hole saw. Choose a hole-saw bit that is slightly larger than the bung. Then carefully cut around the broken bung to remove it. This should give you a clean hole for re-welding the replacement bung.
Install the New Bung
- Clean the area: Thoroughly clean the welding area to remove debris and ensure a good bond.
- Position the new bung: Ensure the bung fits snugly and aligns correctly and then clamp/tack weld into place.
- Weld it: Use appropriate welding techniques and filler material for the DPF material. Consider using a TIG welder for precision. Weld around the entire circumference to ensure a strong, leak-free connection.
- Inspect the weld: Check for any gaps or imperfections in the weld and re-weld if necessary.
- Cooling time: Allow the weld to cool completely before proceeding.
Final Steps
- Thread chasing: Clean and chase the threads in the new bung to remove any debris.
- Install sensor: Apply anti-seize to the sensor and carefully tighten it into the bung.
- Reassemble: Reinstall the exhaust components and secure all connections.
- Check your work: Start the vehicle and check for leaks around the new weld bung.
An Ounce of Prevention - Pro-Tip:
Be sure to apply anti-seize when installing a sensor. This will help prevent bung damage the next time around. REP sensors include a mini tube of anti-seize for this very reason.
Additional Tips
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Take your time: Rushing the process can lead to mistakes.
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Protect surrounding areas: Use masking tape or heat shields to protect nearby components from heat damage.
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Test for leaks: After reassembly, check for exhaust leaks. Don’t skip this step.
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Consider professional help: If you encounter difficulties, don't hesitate to get help from a qualified mechanic or welder.
By following these steps and taking necessary precautions, you can increase your chances of successfully replacing the DPF weld bung.
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DPF Parts Direct has one of the largest selections of Weld Bungs around. Need help figuring out which bung to order? We are here to help. Check out our recent article on the subject and get our free DPF Weld Bung Guide that can help you figure out the correct weld bung.
Still not sure, or need to double-check? No problem. Give us a quick phone call, email, or online chat. One of our US-based parts experts will be happy to answer your questions.
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