Quick answer
A Ford DPF replacement can cost £600–£1,200+ depending on model and part brand. The pressure sensor is often near the bulkhead, connected by two hoses to the filter. Professional cleaning (~£200–£400) can revive moderate blockages. Regular regens are vital to avoid frequent clogging.
Detailed answer
Ford’s diesel lineup—Transit vans, Transit Custom, Kuga SUVs—commonly uses Diesel Particulate Filters (DPFs) to meet emissions standards. Here’s what owners need to know about replacement costs, sensor placement, and cleaning solutions:
1. Replacement Costs
– Price Range: A brand-new Ford DPF often starts around £600 if you source an aftermarket option, but can exceed £1,200 for official OEM parts or bigger models. Vans like the Transit might need a larger filter, especially on higher-output engines, pushing the price higher.
– Labour: Fitting it can run £150–£300, depending on accessibility. The old unit has sensors or clamps that might be rusted. Some owners find independent specialists cheaper than main dealers.
– Dealer Markups: Official Ford parts usually come at a premium. Independent garages sometimes offer reconditioned or reputable aftermarket filters at a lower cost, though quality varies.
2. DPF Pressure Sensor Location
– Bulkhead/Firewall: Many Ford models place the pressure sensor up near the engine bay firewall, with two small rubber or silicone hoses leading down to the DPF region. One hose reads upstream pressure, the other downstream.
– Why It Matters: If these hoses clog or crack, the sensor can’t accurately detect soot load. You might get spurious DPF warnings or failed regeneration.
– Tip: Inspect and clean those hoses periodically, especially if you’re troubleshooting recurring DPF fault codes.
3. Cleaning Options
– Professional DPF Cleaning: Ranging £200–£400, ultrasonic or thermal methods can restore much of the filter’s capacity, removing soot and moderate ash.
– On-Vehicle Solutions: Some garages do chemical flushes through the DPF while it’s still installed. This can help partial blockages but may not fully remove deeper ash.
– Forced Regen: If the DPF is only mildly blocked, a forced regen (via diagnostic tool) might suffice. The mechanic revs the engine at high idle for about 20–30 minutes, superheating the filter.
4. Preventing Frequent Clogs
– Driving Habits: If your Transit or Kuga is used for short local deliveries, you risk never reaching regen temps. Try scheduling a weekly higher-speed run or ensure the engine hits proper operating temperature.
– Check for Engine Faults: EGR, injectors, or turbo leaks can ramp up soot production, overwhelming the filter.
– Proper Oil: Low-ash oil helps reduce residue that the DPF can’t burn off.
5. Sensor Maintenance
– If you see codes referencing differential pressure anomalies or DPF sensor faults, consider cleaning or replacing the hoses and sensor. They’re cheaper than a new filter.
– Ensure the sensor plug is secure; vibration can loosen connections.
Conclusion
For Ford’s Transit, Transit Custom, or Kuga diesels, a DPF replacement can stretch from £600 to over £1,200. Locating the DPF pressure sensor (usually near the bulkhead) allows for quick checks when fault codes surface. If clogging is moderate, a professional clean—around £200–£400—often saves the expense of a new filter. Ongoing prevention, like regular regen-supporting drives and engine maintenance, keeps your Ford’s DPF from becoming a recurring money pit.
