FUEL NIGHTMARE
FTE Legend
Joined: Mar 2017
Posts: 31,976
Likes: 9,200
From: Western NY
I was having so many sensor issues I thought it was just another one going out.
I picked it up from the dealership after they had it over a month trying to repair back-up sensors. I had them service it as well. I filled it up that same day and a couple days I had all the fuel issues.
When I filed the claim I also had to file with the state of Texas so they could go and pull samples from the gas station. Nothing was wrong with the fuel. I attached the report from the samples that were taked.
I picked it up from the dealership after they had it over a month trying to repair back-up sensors. I had them service it as well. I filled it up that same day and a couple days I had all the fuel issues.
When I filed the claim I also had to file with the state of Texas so they could go and pull samples from the gas station. Nothing was wrong with the fuel. I attached the report from the samples that were taked.
"Results and Conclusions: ,
fuel 1, is a fresh biodiesel blend in the range of 1% biofuel. No water, sugar, sand, Diesel Exhaust Fluid (DEF), or another fuel is detected. No particulate is visible but microscopical examination identifies a trace level of rust in the range of 3-5 µm, in size, and pollen. The fuel sample meets the water and sediment requirements of ASTM D975. ,
fuel 2, is a fresh biodiesel blend in the range of 1% biofuel. No water, sugar, sand, Diesel Exhaust Fluid (DEF), or another fuel is detected. No particulate is visible but microscopical examination identifies a low level of rust greater than 10 µm, in size, and pollen, and plant material. The fuel sample meets the water and sediment requirements of ASTM D975."
Looks like you got some fuel, especially the second sample, with bigger and more of rust, pollen and plant material. I'm thinking the bigger pieces of rust caused the failure? And how much is a "identifiable low level of rust particles" in the 10 micron and bigger size? Enough to cause the CP4 to fail?
FTE Legend
Joined: Mar 2017
Posts: 31,976
Likes: 9,200
From: Western NY
FTE Leadership Emeritus
Joined: Sep 2003
Posts: 12,258
Likes: 771
From: Houston, Texas
I worked for a shop in 2020 and they regularly did fuel systems on Duramax and 6.7 Powerstroke trucks. The ticket for this job was usually in the $10,000-11,000 range, $5000 of which was the kit Ford sold to replace the entire fuel system.
If you go to an independent shop you'll spend less. Independent shops are more willing to work with you and usually come out cheaper than the dealer with sometimes better customer service. Do your homework though and ask around
If you go to an independent shop you'll spend less. Independent shops are more willing to work with you and usually come out cheaper than the dealer with sometimes better customer service. Do your homework though and ask around
Lead Driver
Joined: Feb 2022
Posts: 7,995
Likes: 4,061
It sat for a month in a dealers outdoor lot, then after getting it fixed, drove a few days and had issues. Sounds like if there was water, it was from sitting with an open fuel system so moisture could build up.
If rust was found in the fuel tank, was rust found at the CP4? Just because a fuel sample from the tank has some rust, does not mean the rust came from the truck, could have been picked up from the station too, and gets filtered out by the second stage filter. A CP4 though wont grenade immediately, it takes some time before it consumes enough of itself to be an issue. Something doesn't sound right with this.
If rust was found in the fuel tank, was rust found at the CP4? Just because a fuel sample from the tank has some rust, does not mean the rust came from the truck, could have been picked up from the station too, and gets filtered out by the second stage filter. A CP4 though wont grenade immediately, it takes some time before it consumes enough of itself to be an issue. Something doesn't sound right with this.
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4th Gear
Joined: Jun 2024
Posts: 4
Likes: 0
What I think the dealership did was once it saw the error code it stopped looking and spending time on it.
The insurance pulled the sample after the second filter and thats what the results were from. Fuel from the tank was not tested. It was pulled and looked cloudy, and thats what drove for a sample to by analyzed.
Bottom line is that fuel going into the pump was not contimated with water but it did have rust from component failure. Ford's filter system failed to pick particles bigger than 10 microns. Based on the fuel standard, diesel from the pump is allowed 14 micron particles.
2022 has been a bad year for ford. Quality / finish / accesiories was severly impacted by covid. Instead of pushing out crap they opted to make a $. My next move is trading it in.
The insurance pulled the sample after the second filter and thats what the results were from. Fuel from the tank was not tested. It was pulled and looked cloudy, and thats what drove for a sample to by analyzed.
Bottom line is that fuel going into the pump was not contimated with water but it did have rust from component failure. Ford's filter system failed to pick particles bigger than 10 microns. Based on the fuel standard, diesel from the pump is allowed 14 micron particles.
2022 has been a bad year for ford. Quality / finish / accesiories was severly impacted by covid. Instead of pushing out crap they opted to make a $. My next move is trading it in.
Hotshot
Joined: Jul 2013
Posts: 14,302
Likes: 2,197
the new engine bay filters have a by pass feature….supposedly this feature is useful for cold weather operation….so can we expect 14 micro. Particles to collect in our injector screens…..scary
Mountain Pass
Joined: May 2024
Posts: 138
Likes: 93
I stand by my statement. Another smoke up their 🫏 job well done by Ford. The CP4 is a POS that doesn’t belong in the US market, and this response from Ford is not uncommon.
Hey Ford, we all read these forums and see how you treat customers. I personally know you lost 3 diesel sales specifically because of this problem.
Hey Ford, we all read these forums and see how you treat customers. I personally know you lost 3 diesel sales specifically because of this problem.
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From: Western NY
Lead Driver
Joined: May 2021
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From: Uh oh, CA
Wow, I hate to hear this for you. I have always heard $12k being the norm for the repair with some reports of it being lower. I figured this was just due to the labor costs being more or less at different shops. I would have hoped insurance would have stepped up for you since Ford isn’t… this is a good reason to go with a DCR for the replacement though and not have to worry about this again. This is also why I put a S&S DPK on mine pretty soon after getting it. Between the 20+’s being pinned and the DPK I think it’s the best option next to a DCR. And while I do hate to hear this for anyone, I gotta say, besides some pretty minor things my 22 has been very good to me. After reading through the 2017 forums it sounds like the 23+’s are having way more issues than the 21’s and 22’s… which is surprising given these are from the COVID time and that they were supposed to have stepped up QC in 23.
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