We have a 2013 (built in 2012) Monaco Diplomat that has for the last 4 months had serious DPF system issues that have put us in the shop more than on the road. Wondering if anyone else has a Monaco built by Navistar that is having the same issues. Synopsis below - sorry for the length.
We bought the coach in Jan 2014 and since then have had over 127 regens with only a little over 39,000 miles. First year, no problems! Then in Dec 2015 the MIL lamp illuminated indicating a malfunction in emission system and that it need to be checked out. Took it to an International svc center in St. Augustine, FL (Where we live) and they replaced fuel pump and filter after troubleshooting. Also had issue with VIN number in ECM not matching up due to capital and non-capital letters. Had to contact a Navistar repair advocate to get help - motorhome would not run until that was fixed.
3 days after getting motorhome back, we left on 2 Jan to go to AZ - 2nd day into trip, MIL illuminated again and stayed on for 3 days. Noted power loss in TX and took it in and had the primary fuel/water separator filter replaced. Power return but MIL stayed on for the rest of the day. Next 2 days no issues. On return trip from AZ to FL, 30 mins into the first day of driving, stage 3 lamp and alarm came on and we had to pull over and do a parked regen. Next 3 days no issues. 4th day, 1 1/2 hrs into trip, stage 3 lamp and alarm and we pulled over and did a parked regen. Following the successful regen, we started back driving and 20 minutes later got the stage 3 lamp and alarm and pulled over again for a parked regen. We got on the phone and found an International Svc center 3 miles away in Shreveport, LA. Contacted them and they said to bring it in the next morning. We did and they had it for 3 days During that time they detected faults and removed the fuel pump and filter housing and discovered what looked like small rocks in the well of the fuel filter. A new assembly was put on. Another fault was the DPF - the removed it and air pressure cleaned it. Fault of a pressure sensor and DPF fuel injection was next and we believe that they replaced those.
Leaving there and heading back to FL, the next day, we noticed blue and black smoke coming out the exhaust. No lights, no alarms, no loss of power. We continued traveling home and the smoking continued off and on. Took it to Mauldin International in Jacksonville, FL where they replaced the DPF fuel injector gasket and turbo intake air pressure sensor. Took the RV home and during our every 2 week drive of 25 miles, no more issues.
On Mar 15th, we left for Decatur, IN for some extended warranty work on the coach and on day 2 of the trip, the MIL started flashing, smoke, some of power. MIL soon stopped flashing and we traveled to our destination with intermittent smoke from exhaust. Next day, smoke off and on and then 11 miles from CG, stage 1 lamp on and stayed on until we parked at CG. The next day we had to do a parked regen 30 minutes into trip. Smoking. Stage 1 lamp illuminated, stage 2 lamp illuminated but no stage 3. Lamps went off, still smoking next 150 miles to CG. Next morning, 20 minutes into trip, stage 3 lamp and alarm, pulled over and did a parked regeneration. Still smoking. No more alerts before we got to REV Service Center in Decatur, IN
While in Decatur, we contacted an International Svc center in town and made an appointment that Thurs to have it checked out. They found that the DPF was cracked and the seals were blown. A new DPF with core and sensors was installed and the ECM updated.
We left there feeling that finally the DPF System issues were resolved - we had all new stuff!!! NOT - On day 3 of trip back to FL, at 1 1/2 hour into trip, stage3 lamp and alarm do we pulled over and did a parked regen. Once were on back on the road, 45 mins later we had to do another parked regen, the CO alarm was sounding in the bedroom, black smoke, stage 2 lamp illuminated and MIL illuminated. We contacted an International Svc Center nearby in Macon, GA. They told us to bring in the next day. We limped into a CG and the next morning took the motorhome in for health report - they found some codes, fixed them; still getting codes - now think it is an electrical issue. Can't figure out what to do to fix it!!! It has been there 9 days now.
If anyone has had similar issues with the DPF system on Monaco Diesel Pushers built by Navistar and have had resolution, could you please share with us!!!!???
