Check as follows:
1. Using a 9 inch C-clamp (or larger) along with a 2×4 piece of wood, place the 2×4 along the DPF outlet cone
as seen below.
NOTICE
DO NOT hit the 2×4 with a hammer as it could cause damage to the cone.
NOTICE
The desired distance between the Diesel Oxidation Catalyst (DOC) and DPF cone is 289
mm (11.4 in.). Exceeding 289 mm (11.4 in.) could lead to exhaust leaks internal to the 1
BOX ™.
2. Carefully hand-tighten the C-clamp until the desired distance between the DOC and DPF cone is achieved.
3. Remove the C-clamp and 2×4 from the 1-BOX .
4. Install the DPF.
BOX™ Removal and Installation from the Vehicle
Remove as follows:
NOTICE
Tool Graphic
W060589003100
or
DSN0ATZ17001
If the Diesel Oxidation Catalyst (DOC) and/or the Diesel Particulate Filter (DPF) is replaced,
all applicable fault code diagnostics should be completed and the root cause of the failure
must be repaired. Refer to the DDC-SVC-MAN-0208 Heavy Duty Aftertreatment Failure
Guide. Failure to make the necessary repairs may result in a premature failure of the
replacement component. Standard core return procedure requires that the defective DPF
or DOC be returned in the container that the replacement was shipped in.
1. Shut off engine and apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
2. Disconnect the batteries. Refer to OEM procedures.
3. If necessary, remove the passenger side fairing. Refer to OEM procedures.
4. Allow the Aftertreatment System (ATS) time to cool.
Note : The exhaust clamps are directional. Record the location of the clamps for installation.
5. Disconnect the exhaust system inlet pipe by loosening the clamp and relocating the inlet pipe away from
work area. Discard the gasket.
6. Disconnect both 18-pin electrical connectors (1) by squeezing the sides and pulling each connector away
from the mounting bracket.
7. Disconnect the exhaust system outlet pipe by loosening the clamp and relocating the outlet pipe away from
work area. Discard the gasket.
NOTICE
Wait at least five minutes after shutting down the engine to disconnect the DEF lines. To
prevent Diesel Exhaust Fluid (DEF) flow issues, take note of the routing of the DEF lines. If
removed, they MUST be installed according to manufacturer’s specifications to avoid DEF
flow issues and leaks.
8. Note the location and orientation of the DEF pressure electrical connectors and disconnect the DEF
pressure (3) and return (4) line heater electrical connectors at the DEF dosing unit.
NOTICE
To disconnect a DEF line, push the line coupling in towards the male connector to move
the holding clip to the unlocked position. Then compress the prongs of the holding clip
and pull the line off of the male connector. Failure to properly remove a DEF line can
result in damage to a line coupling or DEF port.
9. Note the location and orientation of the DEF lines and disconnect the DEF pressure (2) and return line (1)
from the DEF dosing unit.
10. Disconnect the DEF line mounting bracket nut from the 1-BOX™.
11. Using the ATD lifting device W060589003100 along with the lifting jack TLZ-00785, lightly position the
lifting device under the 1-BOX so that the lifting bars are under the outer tanks without enough force to lift
the 1-BOX or the vehicle. Attach the safety strap to the lifting device.
12. Remove the three bolts (1) and nuts attaching the 1-BOX rear mounting bracket to the vehicle frame rail.
13. Remove the four bolts and nuts (1) attaching the 1-BOX to the front mounting bracket. DO NOT remove the
three bolts attaching the front mounting bracket to the frame.
14. Using tool W060589003100, carefully lower the 1-BOX away from the vehicle ensuring that all exhaust, air,
and electrical harness connections have been disconnected and that the 1-BOX is free from the vehicle.