I'm hoping someone can help me or at least tell me I'm not the only one with this problem.
I bought my Focus 57 plate 1.6 TDCi 18 months ago & the dealer fitted a new DPF just after I bought it due to a DPF error on the display. Since then I've never had any DPF error messages. Over the last 18 months (& 48,000 miles!) forced regenerations have become more & more frequent. When I bought the car I didn't notice any, then I started to notice it was doing one every day (my 90 mile round-trip to work), then every journey, and now they're continuous i.e. 5 mins after I leave home the first cycle starts & lasts about 7 mins, then I get 2 minutes of normal driving before the next regeneration cycle starts. You can imagine what this is doing to my MPG! My commute consists of 30 mins of motorway cruising followed by some clear A-roads & finally 5-10 mins of slow traffic. I cruise at 55-60 on the motorway for economy and, according to what I've read, it should need to do any forced regenerations under those circumstances. I know it's doing the regen by watching the average MPG. I reset it when I leave home & it builds nicely for the first five mins, then starts to drop again while the regen takes place, before recovering a bit in between cycles. When I get out of the car at the end of the journey the cooling fan is always running & I think this usually happens during regen.
Neither my local garage or the Ford main dealer has got a clue. The only diagnostic fault they've seen is a regeneration failure which may have been logged after the EGR fell to bits a few months back & had to be replaced.
I can't afford to replace the DPF on the off-chance that it will cure the problem & in any case I don't think it should be blocked. Could it be a sensor fault? Can the entry/exit pressure sensors be replaced individually at a reasonable cost?