Well it happened to me. On the way home from a camping trip in upstate NY the dreaded CP4 disaster struck! My family and I were stuck on the side of the interstate 5-1/2 hours away from home. I had the truck towed to a Ford dealership that was only 1-1/2 miles from where we broke down because I had no idea where else to tow it to. It is estimated between 12k and 13k to replace the entire fuel system and clean the tank. I had to rent a truck to tow my camper and get my family back home. What a nightmare!!! The ford place said they should have the truck fixed in a week so I have to go back to pick it up. I will get a two year unlimited mileage warranty on all of the parts from Ford.
Here is my dilemma. I ask about adding a disaster prevention kit from S&S to prevent this from ever happening again and was told that would likely void the warranty if the pump fails again because the truck will be considered to have aftermarket parts. This seems stupid on Fords part because if it did happen again the only thing that needs replacing is the fuel pump but without the kit you would have to replace everything again. The labor costs for this repair is probably more than double what the parts are so I will probably have a S&S kit installed anyways.
The service manager said the new pump will be a newer designed CP4 and it should not happen again. Does anyone know if this is true? Are the newer pumps different in some way and I do not need the S&S kit with this "newer designed pump" or is it just more BS? I am pretty much stuck with the truck for now because I still owe on the new to me 2017 truck that I bought last year and now am spending roughly $13,000 on a repair. There is no way I could get close to breaking even by trading or selling the truck. Hoping someone knows the answer about the newer CP4 pumps. I have learned a lot since this has happened by doing a lot of reading and video watching. I will forever be using some additives to help with lubrication of the fuel pump so if you have any suggestions as to what additives work best and how often to add them I will gladly welcome any advice.

Thanks,

 

You might want to ask about a a DCR Conversion.

 

How many miles on the truck?

I am not an expert in this, but the newer design apparently has the roller pinned into where it sits, the bucket, because prior to those rollers which have a tubular bearing which rides on the lodes of the camshaft which spins to open and close each side of the CP4.

When contaminates where encountered or a lack of lubricity from poor fuel, those rollers were able to move in the buckets, because both the roller body and buckets are circular and not pinned, hence causing the tubular roller to be off (because it turned in the bucket) and cause wear on the tubular bearing creating chaos.

More info here;

https://www.ford-trucks.com/forums/1...esign-cp4.html

As to what additives are the best, I will not claim mine is the best but I trust it... I have used K100D since the truck was new.

I started using Pittsburgh Power's rebranded Better Diesel FBC, for the DPF, Max Mileage about 3 years ago and new use it in combo with their newer fuel additive Flashpoint which is similar to K100D but adds more cetane than K100D does. I continue to use to K100D along with FP/MM combo. I tend to over dose as well...

Others will chime in about additive usage as well. My truck currently has about 141k miles with the S&S Gen 2 kit installed in July 2023 with 108k miles.

As to the S&S kit install, if you have a 5 year loan, and now adding 13k more to debt, put the $400 kit on. The CP4s are cheap by themselves, but the parts you now have to buy to replace, probably at least $3.5k to $4k from dealer, the rest is labor to remove and then install new parts.

So adding 400 dollar insurance on to your engine's fuel system is worth it. Once paid off and down the road, you want to have a S&S DCR pump installed, about $2k in price, or if you want it installed now, since they are removing the old CP4, you can go for that as it can handle bad fuel or contamination that the CP4 cannot.

They sell complete 6.7 fuel system kits complete w a DCR instead of a new CP4.

Up to you on what you want to do but I'd say at least get the DPK installed if you will be driving the truck and maybe keeping it longer term.

Good luck.

 

I highly recommend the S&S DPK for anyone running a CP4, even better is replacing the CP4 with a DCR, but I assume the last thing you want to do is sink another $2k into the truck at this point.

As fa as fuel additives, IMHO they are a must. Which one? The one that satisfies your research. As far as I am concerned any lubricity additive is better than no additive.

 

Call your insurance. I had a friend , we'll sort of , put DEF in the fuel tank . 20k plus , and insurance paid all but his 1000 dollar deductible.

 

What warranty is ford talking about?

ford Typically points fingers in every direction ton except themselves when faced with covering a cp4 system repair.


when I bOught my truck new the first thing I did was install a DPK.

in your case see if ford will document the failure was due to bad fuel and then take that document and file a claim with your insurance. I always keep my fuel receipts in case I have to identify the last source of fuel.

 

New ones have pined buckets but they still fail so they are telling you a bunch of bs. Just like there telling you about the warranty, if it happens again they will weasel there where out and say it was contaminated fuel so not covered as only mechanical failure is covered. If I were you I would find an independent shop close by to tow it to and get them to put in a dcr for you.

 

Link us to a Ford denied warranty from this site. From what I recall, all failures that were still under warranty was covered. I believe some of the denied warranty coverage were corrupt dealers.

 

The truck has 157,000 miles on it.

 

157,000 Miles on the Truck

 

bs..link us to cases where ford covered a cp4 repair under warranty.


everyone knows that ford will weasel their way out of covering a cp4 repair.

 

I have fixed 3x trucks were the warranty was denied, in both cases oxidation was found in the HPFP, fuel rail or HPFR on the fuel rail. I know of at least 5 trucks that were repaired under warranty. IMHO it is a hit and miss endeavor so protect yourself with at least a DPK.

 

yes…sad but true…ford finds evidence of oxidation and rather than taken responsibility for a water trap that does not work and a water in fuel sensor that does not work…it’s the operators fault.. hopefully there was a remedy via insurance if ford put to pen the water conclusion.

 

I started a claim with my Insurance company (National General Insurance) today. I will let you know the results when I find out. They stated they did not cover repairs but when I told them it was due to Contaminated Fuel they opened a claim we will see where it goes.

 

My understanding is that this issue comes down to diesel fuel lubricity.

I would look into installing additional/aftermarket fuel filters that you change often to ensure no water or contaminants ever make it to the CP4, while also running fuel additives.