Got the 80% full message again today - have 91,000 miles on now. Never got the first one until about 60K but seem to be getting them more frequently - at least 3 in the last 10K.

Any ideas (other than the delete!)

 

um.... a new one?

 

Dodge and Cummins put together a DVD that covers this issue. They explain that you need to drive the truck at highway speeds above 50 MPH for 40 min or until the over head display shows clear. The truck will regen and burn off the soot in the DPF. This is the theory per Dodge on how to keep the DPF from filling up.
The DVD part number is 68049170AA, part name label, this you can get from your Dodge dealer.

 

Jim - it has 91K in 14 months - it see's LOTS of Highway at 50+! It is rarely anything but highway as it is used for work - we pull RV's to dealers.

 

Have you tried unplugging the EGR and seeing if the truck still runs fine? That will cause the soot to cease AND your mileage should go up a couple of points. It's worth a try but you will need to have the most current flash in the ECM. If you have any issues then you can just simply plug it back in....

 

I have unplugged the EGR but really did not notice an increase in mileage. It ran fine but I did a 250 mile trip with it plugged in and then on the return it was unplugged and the mileage was the same.

 

Well, if you still have it unplugged then you should not be getting so much soot in your engine. Simply unplugging the EGR without doing the blockoff plates will still allow a bit of soot to get into the engine but it is very minimal and should not be causing you to get this message.
Even if your mileage did not go up it is still a good idea to leave the EGR unplugged just to keep the soot down. As long as the truck runs fine that is....