Ford CP4 Fuel Pump Recall: What Every 2020-2022 Ford Super Duty Owner Needs to Know

If you own a 2020 to 2022 Ford Super Duty truck with the 6.7L Power Stroke diesel engine, your vehicle is part of a major recall affecting nearly 300,000 trucks due to a failing Bosch CP4 RP7 high-pressure fuel pump. Ford officially launched Recall No. 24S78 in December 2024, after years of investigation and thousands of warranty claims. The core problem is that biodiesel deposits can build up inside the fuel pump, causing it to fail—often catastrophically. When the pump fails, it can send metal shards through your entire fuel system, leading to repair bills that can exceed $15,000. The fix Ford is offering is a software update to the powertrain control module, not a pump replacement, which has drawn criticism from many owners.

What Models Are Affected by the Ford CP4 Recall?

The recall covers 295,449 vehicles built between February 19, 2019, and August 23, 2021. These are the specific models equipped with the 6.7L Power Stroke diesel engine and the Bosch CP4 RP7 fuel pump:

  • 2020–2022 Ford F-250 Super Duty
  • 2020–2022 Ford F-350 Super Duty
  • 2020–2022 Ford F-450 Super Duty
  • 2020–2022 Ford F-550 Super Duty
  • 2020–2022 Ford F-600 Super Duty
  • 2021–2022 Ford F-650
  • 2021–2022 Ford F-750

If you own one of these trucks, you should have received a recall notice from Ford by mail between January 13 and January 17, 2025. If you didn't get a notice, you can call Ford at 1-866-436-7332 and provide your VIN to check your truck's status.

Why Does the CP4 Pump Fail?

The Bosch CP4 pump was originally designed for European diesel fuel, which has much higher lubricity than the ultra-low sulfur diesel (ULSD) used in the United States. Without enough lubrication, the internal metal components grind against each other instead of rolling smoothly. This creates metal shavings that quickly spread throughout the entire fuel system.

Ford's official explanation points to aged biodiesel deposits as the root cause. During the COVID-19 pandemic shutdowns, many trucks sat parked for long periods, and fuel that had been stored for extended times began to degrade. These deposits form on the pump's roller components, causing premature wear and eventual failure. Ford's investigation found a "positive correlation between bio-mass diesel specifications and average temperatures within a state and the incidence of failures."

What Happens When the CP4 Pump Fails?

This is not a simple breakdown. When the CP4 pump fails, it often grenades—sending tiny metal fragments at over 25,000 PSI into every part of the high-pressure fuel system. The contamination spreads to:

  • All fuel injectors
  • Both fuel rails
  • Every high-pressure fuel line
  • The low-pressure lift pump
  • The fuel tank and pickup assembly
  • Return lines and filters

In severe cases, the pump can seize so violently that it locks up the entire high-pressure system, stalls the engine while driving, and can even cause catastrophic engine damage requiring a full engine replacement.

Symptoms of a Failing CP4 Fuel Pump

Watch for these warning signs. If you notice any of them, stop driving the truck immediately and have it inspected:

  1. Extended engine cranking – The truck takes longer than usual to start, especially in the morning. The pump is struggling to build enough pressure.
  2. Check Engine Light – Common diagnostic trouble codes include P0087 (fuel rail pressure too low), P0191 (fuel rail pressure sensor), and P0088 (fuel rail pressure too high).
  3. Loud rattling or clicking noises – You may hear metallic sounds from the engine bay, indicating metal-on-metal contact inside the pump.
  4. Reduced engine power or sluggish acceleration – The pump is starving the injectors of fuel pressure.
  5. Rough idle, misfires, or sudden stalling – Debris has begun to clog injectors, causing inconsistent fuel delivery.
  6. Metal flakes in the fuel filter – This is a critical red flag. If you or your mechanic find shiny metallic particles in the filter housing, the pump is disintegrating.

What Is Ford's Official Fix?

Ford's remedy for the recall is a Powertrain Control Module (PCM) software update that dealers will perform free of charge. The update is designed to "increase pump cooling and prevent formation of aged biodiesel deposits." However, as of late 2025, the software fix was not yet available for all affected trucks, and Ford plans to notify owners by mail when it is ready.

The diesel community has been highly skeptical of this approach. Critics point out that a software patch cannot undo damage already done to a physically worn pump, and it does nothing to address the fundamental design flaw of the CP4. When Ram faced a similar issue with its Cummins engines, the company replaced the CP4 pump with the proven CP3 design—a hardware fix that actually solved the problem. Ford has not taken that step.

The Cost of a CP4 Failure Without a Recall Fix

If your pump fails and the recall software update doesn't prevent it, you're looking at some of the most expensive repairs in the diesel world. Here are typical costs:

  • Pump-only replacement (minimal contamination): $4,500
  • Pump + injectors: $12,000
  • Full system replacement (pump, injectors, rails, lines): $15,000–$18,000
  • Full system + fuel tank: $22,000 or more

These figures include parts and labor. Some dealerships have recommended full engine replacements when the damage is severe enough.

The Lawsuit Situation

As of mid-2026, the Ford CP4 class-action lawsuit is still active, with no settlement reached. The case is being handled by Hagens Berman Sobol Shapiro LLP, the same firm that secured a $50 million settlement against General Motors for the same Bosch CP4 pump issue in May 2025. Ford has been more resistant to settlement negotiations than GM. The lawsuit alleges that Ford knowingly sold vehicles with a CP4 pump incompatible with U.S. diesel fuel and concealed the defect from consumers. Owners who have already paid for repairs can join the lawsuit at no cost.

What Affected Owners Should Do Now

  1. Check your VIN – Call Ford at 1-866-436-7332 or visit your local Ford dealer to confirm whether your truck is included in the recall.
  2. Document everything – If you've already experienced fuel system problems, keep all repair receipts, warranty claims, and correspondence with Ford. This documentation is crucial for potential reimbursement.
  3. Watch for symptoms – Pay attention to hard starting, check engine lights, unusual noises, and power loss. If you spot metal in your fuel filter, stop driving immediately.
  4. Get the software update – When it becomes available, have the recall performed at a Ford dealer free of charge. Even if you're skeptical, the update may help prevent future issues.
  5. Consider a proactive replacement – Many owners are choosing to replace the CP4 pump with a more reliable CP3 conversion kit before a failure occurs. This can cost around $4,500 to $5,100 but prevents the catastrophic damage that comes with a pump failure.

Recommended Upgrade: KEMSO Fuel Pump

If you're looking for a reliable replacement or upgrade for your Ford Super Duty's fuel system, we highly recommend the KEMSO brand Fuel Pump. KEMSO offers high-performance fuel pumps that are designed as OEM replacements, ensuring a perfect fit and reliable operation. Every KEMSO Fuel Pump comes with a lifetime warranty, giving you peace of mind that your investment is protected. Whether you need a direct replacement or a performance upgrade, KEMSO products are built to handle the demands of your diesel engine. Visit their website to explore their full range of products: https://www.kemsoracing.com/.

Final Thoughts

The Ford CP4 fuel pump recall is a serious issue that affects a huge number of Super Duty trucks. While Ford's software update may help some owners, it's not a complete solution for a pump that has a well-documented design flaw. If you own one of these trucks, stay informed, watch for symptoms, and take action before a failure leaves you stranded with a massive repair bill. For a more permanent solution, consider upgrading to a KEMSO Fuel Pump from https://www.kemsoracing.com/ for reliable performance and lifetime protection.


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