The "Ticking Time Bomb" in Your 2011-2024 Ford Powerstroke: The CP4 Problem

Alright, lets talk about the 6.7L Powerstrokes. Great engine with a lot of power. Every diesel has their problems, and Ford is no exception. The fact that Ford put the CP4 pumps on their powerstroke trucks for so long is beyond me. I feel like it's a bit of a joke in the industry of the Bosch CP4 pumps blowing up. This isn't a matter of if it will happen, it's a matter of when it will happen.

Why the CP4 Pump Fails (The $15,000 Bill)

The Bosch CP4 is designed to use fuel to lubricate it. The problem with this is fuel in the United States is ultra low sulfur, which reduces its lubricity tremendously. Thanks EPA. The CP4 is also designed to hit pressures up to 36,000 psi. So, when you combine a high pressure pump that is designed to pump out pressures higher than the fuel can lubricate, what do you get? If you guessed chaos, then you're the unlucky winner of a $10k-$15k bill. The CP4 sends metal throughout your entire fuel system when it blows. That means: injectors, high pressure fuel lines, return fuel lines, low pressure fuel lines, low pressure fuel pump, filters, your fuel tank, you get the idea. And no, you can't just “flush out” the system. If this sounds like a cheap fix to you, then I wish I had your job. If you're unfortunate enough to have this happen to your Powerstroke here in Yuma, AZ, unfortunately, the CP4 is at the heart of your engine and requires extensive labor to remove, let alone the rest of your fuel system.

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Option 1: The Disaster Prevention Kit (Budget Friendly)

There are ways to mitigate this. We’ll save you the time by saying the only company we recommend for the following options is S&S Diesel. You can use what's called a "Disaster Prevention“ kit. This kit will run you about $400 along labor to install with a shop. This does not prevent your CP4 pump from blowing up, but it does save most of your fuel system from the metal that would have been blasted throughout. This is the budget friendly option that still leaves you with the risk of the CP4 pump blowing up and leaving you stranded, but saves you from a $10k-$15k bill when it does.

Option 2: The S&S DCR Conversion (The Permanent Fix)

The best option for this is to do a DCR conversion by S&S Diesel. A DCR is designed to still hit the pressures the CP4 can hit, but removes the pump out of the direct line of fuel. This means if it were to blow up, there's no chance of metal getting blown throughout your fuel system. The DCR conversion will run about $2500 and labor is intensive on it so count on adding shop labor to that cost. Yes, this isn't convenient and definitely not great for your wallet, but you eliminate a potential breakdown on the side of the road and a $10k-$15k bill at the end of it.

Our Recommendation at Power Forge Diesel

Our recommendation: if you can't afford a DCR conversion yet, spend the money for a prevention kit while you save up for a DCR conversion. The alternative is a massive bill and parked truck if you chose to take your chances. Stop by Power Forge Diesel in Yuma to discuss which option is right for your truck.