that can be a sign of the CP4 pump starting to fail ...... wouldn't hurt to have it checked out in case... could possibly save a $8-10k bill...

 

Found them in mine and it was my CP4. Just got my truck back and it was extremely expensive. Went ahead and upgraded everything while I was in there. Not a good sign whatsoever. Those pumps are prone to failure due to the lack of lubricity in the ULSD. There are class action suits in place because of the Bosche CP4 failures

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Which replacement pump did you go with ??

 

The return fuel is recirculated back into the pump inlet, so the metal flakes just do more damage -- I have read about a filter kit to add to the return line to trap those metal particles -- Adding a lubricant to each tank of fuel is a good idea to help prolong pump life

 

Does the pump use aluminum instead of steel? The flakes did not seem to be Ferrous.


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I went with an RCD (River City Diesel) 10mm Stroker pump CP4.2. I also took the stock lift pump off and replaced it with an AirDog 165 II 4g. Got rid of the entire stock fuel system and put a disaster kit on it as well

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I used, and still use, an additive with every tank and drain the separator every two week but it still happened to me and at only 52k miles. Your stock lift pump will still send air to the HPFP which aids in grenading the pump. Once it starts going out (metal shavings in the canister), it's pretty much too late. You have metal shavings throughout the entire fuel system including both pump, lines, sensor, injectors, et cetera. The best way to avoid having to replace all of that is to install a disaster kit from the jump. That will reroute the shavings directly to the tank and keep it out of your injectors and all. Disaster kit is about $350 and well worth the money in my opinion. If I would have known about the issues with the Bosche CP4 from the beginning, that would have been the first thing I did.

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If you see metal shavings, it's probably too late and they're on their way through your fuel system.

 

Well that’s a bummer.
I guess I’ll put a disaster prevention kit on, drive it, and see what happens. Unless someone has a reason why that is a bad idea.


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The RCD Stroker pump and DDP replacement pumps are basically the Bosch 4.2 on 15+ trucks.... I called both places and confirmed. The RCD stroker is modified to pass more fuel.. But internals are still Bosch... Generally, the issue with Bosch CP4s are with 11-14 trucks - 15 and newer have the modified version which is supposed to better... Bronco - I would have somebody check it out...

 

https://www.voodoodiesel.com/products/exergy-improved-stock-cp4-pump-11-18-ford-6-7l-powerstroke



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Anyone have an update on the class action suit against Ford pertaining the cp4 fuel pump?

 

It's still ongoing and there are several of them in place against different manufacturers.

And maybe the '15+ were revised but I am proof that it can easily happen on a later year. Mine is a '16 with only 52k miles and it still happened to me. I go above and beyond with all of maintenance and am very particular where I get my diesel but it wasn't good enough. I have a buddy that drives commercially with a '17 and he just encountered the same thing only he had 140k miles.

They actually have a conversion kit that allows you to replace the CP4 with a CP3 but not for Ford

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Please correct me I’m wrong on this.
It Looks like when I install my disaster prevention kit I will be pulling the metering unit off of the top of the cp4. That metering unit has a screen that will most likely have metal shavings in it if the pump has failed. If I find those shavings I should plan on replacing the pump, injectors, and the rest of my the high pressure system very soon.
If by some chance the shavings are absent I was likely mistaken as to what I was seeing in my fuel filter housing or the shavings came from some other source. Am I risking any damage in addition to the pump and HP system mentioned earlier if I drive it with the bypass kit in place and hope for the best???
I’m retaining some hope because my magnet would not pick ip the shiny bits in my filter housing. From my research the parts that usually fail are steel on steel.
Not too much hope though, it looks like the steel pistol travels in an aluminum cylinder.


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Ceramic piston in a steel bore with a carbide wear ring -- aluminum is waay too soft to hold the pressure

Usual failures that I have seen are the cam rollers(steel flakes) or the guide pistons(aluminum flakes) in the main housing -- not much failure on the high pressure pistons

 

@broncobilly_69: What fuel additive have you been using?

 

I have been using Stanadyne performance, bit the truck had 158k on it when I bought it and the PO did not use an additive.
Come to think of it, the flakes could have been from the foil top on the Stanadyne bottle. Maybe some flakes off in the tank during fill-ups. [emoji1696]
Is that what you were thinking Heavy??


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Well that might be a possibility but not what I was thinking. I was wanting to see if you had a long term additive use history on a 2015 motor. So when we think thru overall the HPFP issues we could theorize that even the "updated/improved" HPFP will not last without adding a fuel additive.

Since you got the truck at 158k then it drops the HPFP in 10K miles(???)...

I found some shiny flakes/shavings in the fuel filter housing.

I'd have to see those myself just to understand better what you are dealing with. I think it's quite possible the HPFP is going out, could just be junk in the fuel as well.



With all that I'd go back to my previous life in aviation. If I found this type of thing you got to start exploring the system to see how bad it really is. It's A LOT of work but if you already have dumped shavings into the fuel tank you got to clean that out. To which you start at the tank going thru each part to see how far/bad the condition exists....


Would the "disaster kit" help at this point?? Hard to say.....if there's even ONE small chip that hits any one injector that's work to be done.



Do you still have the upper filter you pulled off?? Maybe cutting that open to see the contents can help you know where the particles have traveled.


If I owned a shop where you were the customer with this issue my first question is" how deep down the rabbit hole do you want to go??". We all already know the overall costs at a full system replacement.....


My suggestions: Drop the tank, inspect for whatever is inside and CLEAN the snot out of it. Clean it out like a scientist would do to figure out what's been in there. Figure out the lower pump situation. Might be a full replacement to be sure. Then look to how you could flush the hard lines out to inspect the contents. Maybe there's nothing found, maybe it's the worst thing possible. Then we have to decide on the HPFP, lines and injectors......UUUGhhhhhhh.



Maybe dropping the disaster kit and additional filters (I.E. DieselSite kit of sorts)prior to the lower pump into the system would be a cheap way to see what's happening. Roll the dice....(???)


I read plenty of these types of posts...it's a pure nightmare. I see the ULSD fuel lubrication being the first line issue, second comes owner maintenance to include filters, fuel quality, and using a fuel additive, at third is the actual material design of the pump, then fourth the overall fuel system design.

 

I guess the 2011's can be place in the category of "bulletproofing" relating to the HPFP (Cp4) along with the stock turbo...

 

Good news, I installed the bypass kit today and found no shaving in the screen on the metering unit. The only downside is it won't start now that I have it all put back together. I started a new post about that.

 

What is the "label" of the post? I would like to check it out...

 

I got the fuel filter change required notification on my info screen, not sure if it came on before or after my father in law ran the truck off of the road and bounced it off a power pole. After the crash I had cranked it a bit, trying to start it before I remembered the fuel pump reset button. Even though I had just changed the filters 4,000 miles ago I figured I’d do it again just to be on the safe side and to get in sync with the filter life monitoring that I didn’t know I had.
I found some shiny flakes/shavings in the fuel filter housing. I tried to fish a couple out with a magnet to see if they were steel. The magnet didn’t pick them up.
Thought/suggestions???
2015 CCLB, DRW, 4X4, Lariat ultimate. 167k miles full delete @ 157k mi. SCT Livewire with Tyrant tow tune

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If it's a 99 thru 16 cab and chassis with a rear mounted tank it's called tank delamination,looks like plastic silver fishscale,ford did that coating on can chassis rear behind axle tanks , you must fix it cause it could cause injectors to hang open and burn lift and injection pump up , hope this helps y'all look up thoroughbred diesels tank delamination video he will explain, should have bought a 12 valve Cummins lol just kidding

 

You can run anything in them,oil ps fluid , t cooking oil