Forced Regen Service

Stationary DPF regeneration using factory-level scan tools when your truck can't regen on its own.

When your diesel truck can't complete a passive or active regeneration on its own, soot builds up in the Diesel Particulate Filter (DPF) until the system triggers warning lights, reduces power, or puts the truck into limp mode. A forced regeneration is a controlled, in-shop procedure that uses factory-level diagnostic tools to command the engine to burn off that accumulated soot — getting you back to full power without replacing or removing the filter.

$250-$600

30-60 min

Regen Cycle Time

1,100-1,200°F

Exhaust Temperature

Forced Regen vs. DPF Cleaning

Forced Regen Is Right When:

✓ Soot load is elevated but below 80-85%
✓ The DPF warning light just came on
✓ Passive/active regen was interrupted or failed
✓ No previous forced regen has been done recently
✓ Back-pressure readings are only moderately elevated

Full DPF Cleaning Is Needed When:

✓ Soot load is above 85% or maxed out
✓ Forced regen attempts keep failing
✓ Ash accumulation is high (150,000+ miles)
✓ Back-pressure readings remain high after regen
✓ Regens provide only temporary improvement

Not sure which service you need? We diagnose your system first and recommend the most cost-effective solution. We never upsell a cleaning when a forced regen will solve the problem.

Our Forced Regen Process

Diagnostic Scan

We connect factory-level scan tools (JPRO, Ford IDS/FDRS, or OEM-equivalent) to read soot load percentage, ash load, and any active fault codes affecting the aftertreatment system.

Root Cause Check

Before running the regen, we check for underlying issues that may have prevented passive or active regen — faulty sensors, EGR problems, exhaust leaks, or injector faults that could cause the regen to fail.

Forced Regeneration

With the truck stationary in the shop, we command the regen through scan tools. The engine runs at a set RPM while exhaust temperatures climb to 1,100-1,200°F to burn off accumulated soot. The process takes 30-60 minutes.

Verification

After the regen completes, we verify soot load has dropped to acceptable levels (typically below 10-15%), clear any stored codes, and confirm the aftertreatment system is functioning normally.

Signs You Need a Forced Regen

DPF warning light stays on after driving at highway speed

Truck enters limp mode or reduced-power mode

Active regen cycles keep aborting before completion

Soot load reading between 60-85% on scan tool

Increased exhaust back-pressure readings

Loss of power during acceleration or under load

Check-engine light with DPF-related codes (P2002, P2463, P244A)

Excessive black smoke from the exhaust

Platforms We Service

Ford Power Stroke

6.4L, 6.7L (2008+)

GM Duramax

LMM, LML, L5P (2007.5+)

Ram Cummins

6.7L (2007.5+)

Plus commercial platforms: Freightliner, Kenworth, Peterbilt, International, Volvo, and Mack.

Forced Regen FAQ

What is a forced regen and why does my truck need one?

A forced (stationary) regeneration is a service procedure that uses scan tools to command the DPF system to burn off accumulated soot. Your truck normally does this on its own during highway driving (passive regen) or through automatic active regen cycles. When those fail — due to too much city driving, short trips, sensor faults, or other issues — soot builds up to a level that requires a shop-initiated forced regen.

How much does a forced regen cost?

A forced regeneration typically costs $250-$600 depending on the vehicle platform, diagnostic time, and whether underlying issues need to be addressed first. This is significantly less than a full DPF cleaning ($300-$700) or DPF replacement ($2,500-$4,500+). However, if the soot or ash load is too high, a forced regen alone may not be enough and a full DPF cleaning may be recommended.

What is the difference between a forced regen and a DPF cleaning?

A forced regen burns off soot (carbon particles) by raising exhaust temperatures to 1,100-1,200°F. It cannot remove ash — the non-combustible residue from engine oil that accumulates over time. A full DPF cleaning involves removing the filter from the truck and using a thermal bake-and-pneumatic-pulse process to remove both soot and ash. If forced regens keep failing or only provide temporary improvement, a full cleaning is needed.

Can I do a forced regen myself?

A forced regen requires factory-level scan tools capable of commanding the aftertreatment system. Consumer-grade OBD-II scanners cannot initiate this procedure. Attempting to trigger a regen without proper diagnostic equipment can be unsafe, as exhaust temperatures exceed 1,100°F and the vehicle must remain stationary in a controlled environment away from flammable materials.

How long does a forced regen take?

The regen cycle itself typically takes 30-60 minutes once initiated. Including diagnostic time to read codes, check soot levels, and verify underlying system health, the total shop time is usually 1-2 hours. We will let you know if any additional issues are found during the diagnostic process.

Why does my truck keep needing forced regens?

Repeated regen failures are usually a symptom of an underlying problem. Common causes include excessive idling or short-trip driving that prevents passive regen, a faulty DPF differential pressure sensor, EGR valve issues, leaking fuel injectors, a malfunctioning DOC (oxidation catalyst), or exhaust leaks upstream of the DPF. We investigate the root cause to prevent recurring issues.

Serving Willow Springs, Lemont, Burr Ridge, Hodgkins, Countryside, La Grange, Hickory Hills, Justice, Bridgeview, and the greater Chicagoland area.

Need a Forced Regen?

Call us today to schedule your forced regeneration service. We diagnose first to make sure a regen is the right solution.

Request Appointment Call (708) 839-1515