DPF Repair
DPF Filter Repair – Installing a New Core (New DPF)
DPF filter repair is the solution for a mechanically damaged, cracked, melted or worn-out DPF filter, when cleaning is no longer enough. Instead of the expensive purchase of a new filter, we perform the installation of a new high-quality core and return the filter to factory condition with warranty – you practically get a new DPF at a significantly lower price. FixBox d.o.o. repairs DPF, GPF, CAT and SCR cores for customers from all over Bosnia and Herzegovina, as well as from Germany, Austria and Slovenia.
Watch a DPF filter repair
What Is DPF Filter Repair?
Repair means installing a new core in the DPF filter while keeping the original housing and sensors. This practically gives you a new DPF filter – just as good as fitting a brand-new DPF filter, but at a significantly lower price than a complete OEM replacement.
Unlike DPF filter cleaning, which removes soot and ash, repair is done when the core itself is physically damaged and cleaning cannot help.
When Is Repair Needed Instead of Cleaning?
Repair by installing a new core is the right solution if the DPF is:
- mechanically damaged or cracked,
- melted due to overheating and failed regenerations,
- worn out after high mileage,
- damaged by a fault in components upstream of the DPF,
- in a state where cleaning can no longer restore its function.
If you are not sure whether cleaning is enough or repair is needed, we determine the exact condition of the core through diagnostics.
How Do DPF Filters Crack and Melt?
In the vast majority of cases a DPF filter does not crack on its own, but because of a fault or improper handling. The most common causes of a core cracking or melting are:
- Improper "cleaning" by resetting parameters – instead of actually cleaning, some mechanics simply reset the DPF parameters on the diagnostic tool (they set the soot mass to zero, as if a new filter had been fitted) and then run a forced regeneration on a full filter. The accumulated soot then burns uncontrollably, the temperature spikes suddenly and the core melts or cracks.
- accumulated ash together with an excessive regeneration temperature,
- a faulty injector that injects too much fuel (post-injection), so the temperature in the filter exceeds the limit,
- thermal shock – a sudden temperature change on a red-hot core,
- prolonged driving with a heavily clogged filter and constant failed regenerations.
That is why cleaning and regeneration should be done by a workshop that first determines the actual condition of the filter. When the core is not damaged, machine DPF filter cleaning is enough.
How to Recognise a Cracked or Damaged DPF Filter?
A cracked DPF filter has recognisable signs:
- soot at and around the exhaust tip – if you run a finger along the inside of the exhaust and it leaves a black soot mark, the DPF is most likely cracked (a healthy DPF leaves no soot marks),
- regeneration does not complete or the back-pressure does not drop even after regeneration,
- black smoke from the exhaust,
- fault codes that return immediately after being cleared,
- a visibly damaged or melted core on visual inspection.
DPF Filter Repair – Installing a New Core Step by Step
We perform the repair by replacing the damaged core with a new one while keeping the original housing and sensors. The procedure looks like this:
- opening (cutting) the housing of the DPF filter,
- removing the damaged or melted core,
- installing a new high-quality core (DPF, GPF, CAT or SCR),
- welding the housing and checking for leaks,
- adaptation on the diagnostic tool and a forced regeneration – now done correctly, with the new core, so the parameters and soot mass are calibrated as they should be.
The result is a practically new DPF filter which, with proper maintenance, can last at least 200,000 km.
Repair of DPF, GPF, CAT and SCR Cores
We repair all types of emission filters by installing a new core:
- DPF core (diesel engine particulate filter),
- GPF core (petrol engine particulate filter),
- CAT – catalytic converter core,
- SCR core (AdBlue system).
For passenger vehicles, vans and commercial vehicles of all makes.
If the DPF Has Already Been Removed and Deactivated in Software
If the DPF was previously removed (gutted) and switched off in software, we return the vehicle to its factory, legal condition:
- installing a new high-quality DPF core,
- restoring the factory function of the DPF system,
- software reactivation and calibration,
- complete testing – the vehicle passes TÜV and the roadworthiness test without problems.
The vehicle is returned to fully factory condition, in line with the environmental standards (EURO 5/6).
What You Get With DPF Filter Repair
- a practically new DPF filter with warranty,
- a lifespan of at least 200,000 km with proper maintenance,
- smooth engine operation with no limp mode and no fault codes,
- passing the roadworthiness test and TÜV,
- a significantly lower price than buying a new filter.
Repair or a New DPF Filter?
A new original (OEM) DPF filter is often very expensive. Repair by installing a new core gives you the same effect – a new filter – at a significantly lower price, with warranty and a TÜV pass.
DPF Filter Repair Price
The price of DPF filter repair depends on the type of vehicle and the condition of the filter, and ranges roughly from 600 KM (approx. €300) up to a few thousand KM. It is still significantly cheaper than buying a new original (OEM) DPF filter. For the exact price, contact FixBox.
Most Common DPF Fault Codes With a Damaged Filter
- P2002 – DPF efficiency below threshold,
- P244A / P244B – DPF back-pressure (differential pressure) too low or too high,
- P242F – ash accumulation above the limit,
- P2453 – DPF differential-pressure sensor signal fault.
These fault codes can also mean the core is damaged or cracked. Through diagnostics we confirm whether repair is needed or cleaning is enough.
DPF Filter Repair for All Vehicle Makes
- VW, Audi, Škoda, Seat
- BMW, Mercedes-Benz
- Ford, Peugeot, Citroën, Renault, Opel, Fiat
- and other passenger vehicles, vans and commercial vehicles
Related Services
If the core is not damaged but only clogged, machine DPF filter cleaning is probably enough. For AdBlue/SCR system problems, see our AdBlue and SCR service.
Frequently Asked Questions (FAQ)
What is DPF filter repair?
Repair is the installation of a new core in the DPF filter while keeping the original housing. You practically get a new filter at a lower price than an OEM replacement.
How does a DPF filter become cracked or melted?
Most often due to improper handling – resetting the parameters and running a forced regeneration on a full filter, a faulty injector, or overheating. The core then cracks or melts and repair is needed.
How do I know my DPF is cracked?
The most common sign is soot at the exhaust tip (a black mark), black smoke, a regeneration that does not complete, and fault codes that return immediately after being cleared.
When is repair needed instead of cleaning?
When the core is mechanically damaged, cracked, melted or worn out, so cleaning can no longer restore its function.
How long does a repaired DPF filter last?
With proper maintenance and a properly running engine, a repaired DPF can last at least 200,000 km.
How much does DPF filter repair cost?
The price ranges roughly from 600 KM (approx. €300) up to a few thousand KM, depending on the vehicle and the condition of the filter – still significantly cheaper than a new OEM filter.
Do I get a warranty on a repaired DPF filter?
Yes. We provide a warranty on repair by installing a new core, and the vehicle passes the roadworthiness test and TÜV.
Book a DPF Filter Repair
If your DPF is cracked, melted or worn out, get in touch for a repair by installing a new core, with warranty.