Skip to content
Complete Cummins Exhaust System Maintenance Guide
July 21, 2025

Complete Cummins Exhaust System Maintenance Guide

Owning a Cummins diesel truck means enjoying legendary durability and power—but even the toughest engines need proper care. Your exhaust system plays a critical role in performance, fuel efficiency, and emissions compliance. Neglecting it can lead to clogged DPFs, excessive backpressure, turbo strain, and even costly repairs.
This comprehensive maintenance guide will walk you through essential exhaust system checks and services every 50,000 miles, helping you maximize power, avoid breakdowns, and extend your Cummins’ lifespan.

Why Cummins Exhaust Maintenance Matters

Your truck’s exhaust system does more than just expel gases—it controls emissions, regulates backpressure, and impacts turbo efficiency. Key components include:
  1. DPF (Diesel Particulate Filter) – Traps soot; requires cleaning or regeneration.
  2. EGR (Exhaust Gas Recirculation) System – Reduces NOx emissions but can clog.
  3. Turbocharger & Downpipe – High heat and pressure demand inspection.
  4. Exhaust Manifold & Piping – Cracks or leaks hurt performance.

Skipping maintenance leads to:

  1. Reduced MPG (from clogged filters)
  2. Loss of power (increased backpressure)
  3. Failed emissions tests (DPF/EGR issues)
  4. Turbo damage (from excessive heat/stress)

The 50,000Mile Cummins Exhaust Checklist

1. Inspect & Clean the DPF (Diesel Particulate Filter)

Symptoms of a clogged DPF:

  1. Frequent regeneration cycles
  2. Loss of power or throttle response
  3. Check engine light (P2002, P2463 codes)

Solutions:

  1. Forced regeneration (via scan tool)
  2. Professional DPF cleaning (ultrasonic or thermal)
  3. DPF delete pipe (offroad only) – Eliminates future clogs

2. Check the EGR Valve & Cooler

Common EGR problems:

  1. Carbon buildup restricting airflow
  2. Cooler leaks causing coolant loss

Maintenance tips:

  1. Remove and clean the EGR valve (or replace if stuck)
  2. Flush the EGR cooler if clogged
  3. Consider an EGR delete kit (offroad only) for longterm reliability

3. Examine the Turbocharger & Exhaust Manifold

Warning signs of trouble:

  1. Excessive turbo lag
  2. Oil leaks near the turbo
  3. Cracked exhaust manifold (loud ticking noise)

What to do:

  1. Check for shaft play in the turbo
  2. Retorque manifold bolts (common loosening issue)
  3. Upgrade to a highflow exhaust manifold if cracked

4. Inspect the Full Exhaust System for Leaks

Common leak points:

  1. Downpipe gasket (turbo connection)
  2. Clamps & joints in the piping
  3. Muffler or resonator welds

Fix leaks ASAP to prevent:

  1. Soot buildup under the truck
  2. Loud exhaust drone
  3. Reduced boost pressure

Bonus: 3 Pro Tips for Cummins Owners

  1. Use a HighQuality Diesel Additive – Helps keep the DPF cleaner between services.
  2. Monitor EGTs (Exhaust Gas Temps) – Crucial for towing/heavy loads.
  3. Upgrade to a HighFlow Exhaust – Less restriction = better performance & longevity.

Keep Your Cummins Running Strong – Shop Maintenance Parts Today!

A wellmaintained exhaust system means better power, fuel economy, and reliability. Whether you need DPF cleaning supplies, EGR solutions, or performance exhaust upgrades, we’ve got you covered.
Ready to service your Cummins? Browse our full selection of diesel maintenance parts now!
Previous article 7 Warning Signs of a Clogged EGR Valve: Ford F-150 Owners Must Read
Next article Maximize Performance: How to Install a DPF Delete Pipe on Your 2014-2018 RAM Ecodiesel

Leave a comment

* Required fields

Featured collection

  • Seguler 1986-1995 Ford F150 F250 F350 Mustang Trucks EGR Simulator Eliminator / Block Off Plate Kit

    SEGULER
    $74.58 - $74.58
    $74.58
    $74.58 - $74.58
    $74.58

    Block Off Plate Material: Aluminum alloy. Easy installation,and convenient to use. Made of CNC milled from aircraft grade Billet aluminum. Will N...

    View full details
    $74.58 - $74.58
    $74.58
    $74.58 - $74.58
    $74.58

  • For 1996-2004 3.8L 4.6L 5.4L Ford GT SVT GT500 V8 Mustang Cobra EGR Delete kit And Exhaust Cap

    SEGULER
    $51.99 - $51.99
    $51.99
    $51.99 - $51.99
    $51.99

    Placement on Vehicle:Front Billet aluminum IAC (idle air control) and EGR (exhaust gas recirculation) block-off plates add a distinctive touch to ...

    View full details
    $51.99 - $51.99
    $51.99
    $51.99 - $51.99
    $51.99

  • For 2004-2005 6.6L Chevy GMC Silverado LLY Duramax Diesel EGR Delete Kit

    SEGULER
    $87.99 - $87.99
    $87.99
    $87.99 - $87.99
    $87.99

    Material: Aluminum,Stainless steel,Silicone Eliminates soot build-up and clogged EGR Valves Direct replacement. No installation instruction. No Gl...

    View full details
    $87.99 - $87.99
    $87.99
    $87.99 - $87.99
    $87.99

  • For 2011-2016 6.6L GMC Chevy Duramax Diesel LML EGR Valve Cooler Delete Kit

    SEGULER
    $66.49 - $66.49
    $66.49
    $66.49 - $66.49
    $66.49

    Material: Stainless steel, billet aluminum. Eliminate soot and block of EGR valve prevent high EGT from flow back into engine. Quicker turbo spoo...

    View full details
    $66.49 - $66.49
    $66.49
    $66.49 - $66.49
    $66.49

  • For 2011-2019 6.7L Ford Powerstroke Diesel EGR Delete Kit

    SEGULER
    $109.99 - $109.99
    $109.99
    $109.99 - $109.99
    $109.99

    Material: Aluminum alloy,Stainless steel. Exhaust cover plates for EGT probes in Ford factories. CNC machine of billet aluminum and stainless stee...

    View full details
    $109.99 - $109.99
    $109.99
    $109.99 - $109.99
    $109.99

  • For 2006-2007 6.6L Chevrolet Silverado Classic GMC Duramax LBZ Diesel EGR Valve Cooler Delete Kit

    SEGULER
    $60.49 - $60.49
    $60.49
    $60.49 - $60.49
    $60.49

    Material: Aluminum,Stainless steel,Silicone Eliminates soot build-up and clogged EGR Valves Guaranteed to last under high temperatures and pressu...

    View full details
    $60.49 - $60.49
    $60.49
    $60.49 - $60.49
    $60.49

  • For 2011-2023 6.7L Ford Powerstroke Diesel EGR Delete Kit

    SEGULER
    $85.99 - $85.99
    $85.99
    $85.99 - $85.99
    $85.99

    Material: Aluminum alloy,Stainless steel. CNC machine of billet aluminum and stainless steel more durable. Exhaust cover plates for EGT probes in ...

    View full details
    $85.99 - $85.99
    $85.99
    $85.99 - $85.99
    $85.99

  • For 2010-Present Stage 2 ISX 15 CM2250 CM2350 EGR Delete Kit

    SEGULER
    $57.99 - $57.99
    $57.99
    $57.99 - $57.99
    $57.99

    Material: Aluminum Two plates in this kit are made of 6061 aircraft grade billet aluminum anodized and CNC laser cut or CNC machined out of high q...

    View full details
    $57.99 - $57.99
    $57.99
    $57.99 - $57.99
    $57.99

  • Seguler 2009-2019 6.7L Ram Cummins Coolant Bypass Barb Adapter Leak Repair Kit

    SEGULER
    $35.99 - $35.99
    $35.99
    $35.99 - $35.99
    $35.99

    Made of aerospace-grade billet aluminum. Effectively repair the problem of coolant leakage. Resist corrosion and rust for a long time and has good...

    View full details
    $35.99 - $35.99
    $35.99
    $35.99 - $35.99
    $35.99

  • Seguler 2003-2007 6.0L FORD Powerstroke Diesel EGR Cooler Delete Kit

    SEGULER
    $56.14 - $56.14
    $56.14
    $56.14 - $56.14
    $56.14

    Material: 304 stainless steel,Aluminum billet. Eliminate ash accumulation and EGR valve blockage. Improve the cooling effect and reduce the engi...

    View full details
    $56.14 - $56.14
    $56.14
    $56.14 - $56.14
    $56.14

  • For 2014-2019 3.0L Dodge Ram 1500 EcoDiesel EGR Valve & Cooler Delete Kit

    SEGULER
    $70.99 - $70.99
    $70.99
    $70.99 - $70.99
    $70.99

    Material: Aluminum,Stainless steel,Silicone. Eliminates soot build-up and clogged EGR Valves. EGR removed and the temperature in the engine compa...

    View full details
    $70.99 - $70.99
    $70.99
    $70.99 - $70.99
    $70.99

  • For 1983-1997 Ford F150 F250 F350 Mustang Trucks EGR Delete Block Off Plate Kit

    SEGULER
    $22.87 - $22.87
    $22.87
    $22.87 - $22.87
    $22.87

    Material: Aluminum alloy. Easy installation,and convenient to use. Made of CNC milled from aircraft grade Billet aluminum. Will Not Warp or Deform...

    View full details
    $22.87 - $22.87
    $22.87
    $22.87 - $22.87
    $22.87

  • Seguler 2003-2007 6.0L Ford F250 F350 Powerstroke Diesel EGR Basic Cooler Kit

    SEGULER
    $79.99 - $79.99
    $79.99
    $79.99 - $79.99
    $79.99

    CNC machine of Aluminum and Stainless Steel billets. Resist corrosion and rust for a long time and has good heat dissipation. Reduce component a...

    View full details
    $79.99 - $79.99
    $79.99
    $79.99 - $79.99
    $79.99

  • For 2011-2023 6.7L Ford F250 F350 F450 F550 Powerstroke Diesel EGR Valve Delete Cooler Delete Kit

    SEGULER
    $55.99 - $55.99
    $55.99
    $55.99 - $55.99
    $55.99

    Material: Aluminum alloy,Stainless steel. Black Anodized components for better durability. Exhaust Cover Plate Tapped for Ford Factory EGT Prob...

    View full details
    $55.99 - $55.99
    $55.99
    $55.99 - $55.99
    $55.99

  • Seguler 2011-2016 6.6L GMC Chevy Duramax Diesel LML Up-Pipe & EGR Valve Cooler Delete Kit

    SEGULER
    $163.86 - $163.86
    $163.86
    $163.86 - $163.86
    $163.86

    Material: 304 Stainless Steel. Reduce the amount of carbon deposited from exhaust to intake. Thanks to its fast airflow and superior engineered ex...

    View full details
    $163.86 - $163.86
    $163.86
    $163.86 - $163.86
    $163.86

  • For 11-23 Ford 6.7L Powerstroke CCV/PCV Reroute/Delete Engine Ventilation Kit

    SEGULER
    $72.00 - $72.00
    $72.00
    $72.00 - $72.00
    $72.00

    Material:Aluminum alloy rubber. Black Anodized components for better durability. This Crankcase Ventilation System provides a SOLID solution to ...

    View full details
    $72.00 - $72.00
    $72.00
    $72.00 - $72.00
    $72.00

  • For 2017-2023 6.6L Chevy GMC Duramax L5P diesel EGR Valve Cooler Delete kit

    SEGULER
    $131.99 - $131.99
    $131.99
    $131.99 - $131.99
    $131.99

    Material:Aluminum Alloy ,Stainless steel,Silica gel Improved Performance: Eliminating the EGR system leads to better exhaust flow and faster tur...

    View full details
    $131.99 - $131.99
    $131.99
    $131.99 - $131.99
    $131.99

  • For 2007-2010 Cummins ISX CM871 EGR Plug Kit Stage 2 Plates and Plugs Aluminum

    SEGULER
    $62.99 - $62.99
    $62.99
    $62.99 - $62.99
    $62.99

    Material:304 Stainless Steel & Billet Aluminum. High-temperature graphite gaskets are adopted to prevent leakage. Used to delete the EGR val...

    View full details
    $62.99 - $62.99
    $62.99
    $62.99 - $62.99
    $62.99

  • Seguler 2010-2024 6.7L Dodge Ram Cummins Diesel EGR Valve Cooler Delete Kit

    SEGULER
    $89.99 - $89.99
    $89.99
    $89.99 - $89.99
    $89.99

    Material: Aluminum alloy,silicone This kit is intended for off road use. Eliminates soot build up and clogged EGR Valves. Hot exhaust gasses ar...

    View full details
    $89.99 - $89.99
    $89.99
    $89.99 - $89.99
    $89.99

  • For 1986-1995 2.8L 4.9L 5.0L 5.8L 7.5L Ford F150 F250 Bronco EGR Simulator Eliminator Delete/EGR Delete

    SEGULER
    $59.99 - $59.99
    $59.99
    $59.99 - $59.99
    $59.99

    isconnect your stock EGR valve and breathe life into your motor, while keeping your check engine light off, but active for future problems! This ...

    View full details
    $59.99 - $59.99
    $59.99
    $59.99 - $59.99
    $59.99

  • Seguler 2017-2019 L5P Duramax Diesel 4pcs L5P Can Bus Plugs Connector Replacement

    SEGULER
    $59.99 - $59.99
    $59.99
    $59.99 - $59.99
    $59.99

    Material: ABS For use with an Aftermarket Exhaust System. A new engine calibration is required. Plugs will replace NOX and DEF modules. The L...

    View full details
    $59.99 - $59.99
    $59.99
    $59.99 - $59.99
    $59.99

  • Seguler 2020-2023 chevy duramax L5P Diesel Can Bus Plugs Connector

    SEGULER
    $69.99 - $69.99
    $69.99
    $69.99 - $69.99
    $69.99

    For use with aftermarket exhaust systems or delete pipes Used when removing the DPF/DEF systems These plugs will go in place of the NOx and DEF mo...

    View full details
    $69.99 - $69.99
    $69.99
    $69.99 - $69.99
    $69.99

  • For 2007-2010 6.6L Chevy GMC LMM Duramax EGR Valve Cooler Delete Kit Fit

    SEGULER
    $61.99 - $61.99
    $61.99
    $61.99 - $61.99
    $61.99

    Material: Aluminum alloy,Stainless steel. Improves engine life by eliminating soot build-up and reducing fuel consumption. EGR valve cooler delet...

    View full details
    $61.99 - $61.99
    $61.99
    $61.99 - $61.99
    $61.99

  • For 2007-2010 6.6L Duramax LMM EGR Delete Kit High Flow Intake Elbow Pipe Tube

    SEGULER
    $94.99 - $94.99
    $94.99
    $94.99 - $94.99
    $94.99

    Material: Aluminum alloy,Stainless steel. Eliminates soot build up and clogged EGR Valves. Prevent clogging and overheating to reduce the possib...

    View full details
    $94.99 - $94.99
    $94.99
    $94.99 - $94.99
    $94.99

  • For 2007-2009 6.7L Dodge Ram Cummins Diesel EGR Delete Kit

    SEGULER
    $83.49 - $83.49
    $83.49
    $83.49 - $83.49
    $83.49

    Material: Aluminum alloy,Stainless steel,Silica gel This kit is intended for off road use. Eliminates soot build up and clogged EGR Valves. Cool...

    View full details
    $83.49 - $83.49
    $83.49
    $83.49 - $83.49
    $83.49