The factory CP4 high-pressure fuel pump on the 6.7L Powerstroke can fail without warning and push metal debris through injectors, rails, and lines — a five-figure repair. We specialize in preventing that failure, eliminating it permanently, and rebuilding systems after it happens.
The CP4 pump was not designed for U.S. diesel fuel lubricity. When it wears internally, it sheds metal into the high-pressure fuel circuit — and by the time the truck stumbles, the contamination has usually reached the injectors and rails. Many failures happen between 60,000 and 80,000 miles with no warning at all.
Pricing reflects parts and labor for the listed fitment. Final quote may vary by truck condition and location. Fleet pricing available for multiple units.
| Disaster Prevention Kit | DCR Conversion | |
|---|---|---|
| Best for | Owners protecting a healthy fuel system on a budget | Owners who want the CP4 risk gone permanently |
| What it does | Contains pump debris before it reaches injectors, rails, and lines | Replaces the CP4 with a heavy-duty DCR pump |
| Long-term outcome | A pump failure stays a pump replacement — not a system rebuild | The failure point no longer exists on the truck |
| Investment | $1,400 installed | $4,700 installed |
Most CP4 failures give little or no warning — but if you see any of these, stop driving and call:
Continuing to run a failing CP4 pushes more metal downstream and turns a conversion into a rebuild.
Get It Checked
If your fleet runs F-250 through F-550 trucks on the stock CP4 pump, one failure can idle a truck for weeks and cost more than converting several. We schedule prevention and conversion work across multiple units at your yard — ask for fleet pricing.
Same idea, different platform — engineered-in weak points we remove before they take a truck out of service.
The intake grid heater bolt loosens, arcs, and drops into cylinder six. Banks Monster-Ram intake and Killer Grid Heater removes the part that fails.
$1,950 installed — on sale
Grid Heater Fix →GM's 6.6L LML runs the same family of CP4 pump. Converting back to the Bosch CP3 retires the risk — no tuning required.
From $4,700 installed
CP3 Conversion →The factory thermal bypass strangles transmission cooler flow and can stick shut. A billet full-flow replacement stops the heat damage.
From $500 installed
Cooler Bypass →Every documented failure we fix at a flat installed price, with what it costs to head off and what it costs to ignore.
See The Full List →The CP4 was not designed for the lubricity of U.S. diesel fuel. As it wears internally, it sheds metal into the high-pressure fuel circuit.
By the time the truck stumbles, that contamination has usually already reached the injectors and rails — which is why the repair bill jumps from a pump to a whole system.
Many failures happen between 60,000 and 80,000 miles, often with no warning at all.
There is no mileage at which the truck becomes safe, which is why prevention or conversion is the cheaper play at any point in the truck's life.
The Disaster Prevention Kit ($1,400 installed) contains pump debris before it reaches injectors, rails, and lines — so a pump failure stays a pump replacement instead of becoming a full system loss. It is the budget-conscious way to protect a healthy fuel system.
The DCR Conversion ($4,700 installed) replaces the CP4 with a heavy-duty DCR pump, so the failure point no longer exists on the truck. Both fit 2011–2024 Ford 6.7L Powerstroke.
Hard starts or long cranking especially when cold, rough idle, stumble or sudden power loss, metallic debris in the fuel filter at service, fuel pressure fault codes such as P0087, and unexplained fuel-system warning lights.
If you see any of these, stop driving. Continuing to run a failing CP4 pushes more metal downstream and turns a $4,700 conversion into a $12,000 rebuild.
A full fuel system rebuild at $12,000 installed: a DCR conversion plus injectors, rails, lines, and gaskets, with the contamination fully cleared.
Everything downstream of the pump has to go because debris that has been through the system at those pressures cannot be flushed out of it.
Tell us your truck's year, mileage, and how it works for a living — we'll recommend the right option.