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How DPF Weld Bungs Can Save You Thousands

The DPF (Diesel Particulate Filter) and DOC (Diesel Oxidation Catalyst) are some of the most expensive parts of your emissions system, so when one of your sensors gets stuck in its housing or breaks off, replacing the entire unit is a big expense. With our online selection of replacement DPFs and DOCs (Diesel Oxidation Catalysts), you can save thousands by just replacing weld bungs instead of the entire filter. This entire filter contains precious metals to start the oxidation of hydrocarbons.

weld bungs - DPF Parts Direct

Uses for Weld Bungs in a Diesel Emissions Systems

Bungs are used to keep sensors stable and in the right place in the after-treatment system. Temperature, back pressure, O2, particulate matter, and NOx are all closely monitored to ensure the emissions components are operating to spec.

When you look at the emissions system, the location of the sensors will differ depending on your truck’s make and model, but where they are along the emissions system is pretty standardized. These sensors are placed to ensure each step in the system is working properly.

Different sensor types and manufacturers use different sizes, threads, and configurations in their bungs. There are also several types of shapes and flares for a perfect fit. Our weld bungs are made of stainless steel to match the specifications of the OEMs.

Causes of Sensors Stuck in Welded Bungs

The most common reason that sensors get stuck in their fittings is due to galling. This is when two components, such as your sensor and its bung, rub together repeatedly and wear down. The heavy-duty after-treatment system is notorious for causing galling due to both harsh environments and extreme temperature fluctuations.

With enough time and pressure, galling can cause enough friction that will result in a commonly welded sensor to the bung. At that point, it is nearly impossible to separate the parts. Attempting to remove galled sensors will strip the bung’s threads or break the bung off the DPF or DOC altogether.

weld bung - DPF Parts Direct

Another cause of sensors getting stuck is the use of low-quality weldable bungs and sensors. If the threads of your sensor or bung are weak, damaged, or defective, you will likely have trouble removing the sensor in the future.

Choosing the Correct Replacement Bung

How can the customer be sure they're buying the right weld-in bung? It can be tricky when you’re buying online. Your best bet is to measure the thread size and pitch of the bung, with this information and the type of flare we can determine which bung you need. You can also find the OEM part number of the DPF or DOC where the bung is seated, and give us a call and we will try to locate it for you. Standard bungs are commonly available in sizes M10 through M22 and thread pitches 1.0, 1.25, and 1.5. The flare and fitting type are important to note as well.

These bungs need the proper fit to prevent leaks in the exhaust system. An incomplete or insecure housing could result in decreased engine performance and increased fuel consumption from the gas tanks. This could also result in possible exposure to harmful diesel fumes. Trying to make a sensor the wrong size bung will have a similar effect. All of these situations also run the risk of the sensor breaking loose during operation, which would likely send the truck into limp mode.

accept common fittings - DPF Parts Direct

When to Replace Weld Bungs and Sensors

If your sensor has become galled into its bung, breaking the sensor or the threaded weld-in bung is likely. However, if neither part will budge, you may need to apply heat or cut the bung and sensor free. Once the old bung and sensor are removed, you can weld on a new bung and install a new sensor. By welding on a new sensor housing, you avoid the cost of buying a new DPF or DOC.

If you can remove the sensor intact, it's often better to replace it rather than try to reinstall the old one. The removal process can harm sensitive electronics. While it may work when reinstalled, failing 100 miles down the road will cost not only the price of a new one, but also a tow bill, missed deliveries, and planned downtime.

Finally, whenever you install a new sensor, remember to use anti-seize! It’s the best step you can take to prevent galling between your sensor and housing.

Where to Buy Welded Bungs Online? | National Pipe Thread Offerings

No matter the size, NPT (national pipe thread), or if you're concerned if it will accept common fittings, DPF Parts Direct is the place to get your DPF bungs.

oil bags - DPF Parts Direct

DPF Parts Direct makes browsing the best metal bungs for sale easy and painless by avoiding the dreaded supplier delays that have plagued this country for some time now. Our weld on bungs are paired with temperature sensors, backpressure sensors, O2 sensors, and NOx sensors.

We offer the following bung sizes with many options and flares available:

10mm

  • M10 x 1.25

12mm

  • M12 x 1.0
  • M12 x 1.25
  • M12 x 1.50

14mm

  • M14 x 1.25
  • M14 x 1.50

16mm

  • M16 x 1.00
  • M16 x 1.50

18mm

  • M18 x 1.50

20mm

  • M20 x 1.50

22mm

  • M22 x 1.50

We carry bungs from Redline Emissions Products®, which are precisely manufactured to fit as well as or better than OEM, and are made of high-quality materials.

To help customers find the weld-in pipe bung they're looking for, search the “Tags” section to select the type or thread size/pitch of the bung. The “Tags” section is in the sidebar to the left on the desktop and at the bottom of the page on mobile.

Conclusion

Still not sure? We have a team of experts ready to take your call and answer your questions about welding bungs. Be sure to have your DPF or DOC OEM number available when you call so that you can efficiently shop & add the desired items & tools to your shopping cart and be on your way.

This one small part, which can cost as little as $15-$30, can save you thousands on a potentially more expensive purchase down the road.

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  • Steve Hoke