Ford fuel pump recall

Dick Noble

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There is a recall for certain Ford super duty trucks NHTSAV- 457. Dealer will reprogram for free. Letters should be mailed out 1-13-2025. My 2022 F450 is under this recall. This involves the fuel pump. You can call 866-436-7332 for more info.
 
This is a very interesting recall on the CP4 and biodiesel deposits. I was warned by Bosch about not using biodiesel in my '01 Cummins with a VP44 pump - would void the warranty.

 
There is a recall for certain Ford super duty trucks NHTSAV- 457. Dealer will reprogram for free. Letters should be mailed out 1-13-2025. My 2022 F450 is under this recall. This involves the fuel pump. You can call 866-436-7332 for more info.
 
Tried to get in line for this recall but dealer does not have the new codes for it yet and has no idea when they will be available.
 
There is a class action lawsuit with GM for the CP4 fuel pump. If Fird deems it worthy of a recall, I sure hope GM follows their lead.
 
Why Ford continues to use this pump in their diesel trucks is beyond me. Of the big 3, they are the only ones still using it. Just that alone would keep me from purchasing one....
 
Why Ford continues to use this pump in their diesel trucks is beyond me. Of the big 3, they are the only ones still using it. Just that alone would keep me from purchasing one....
It would be interesting to see Ford's rational. Is it if they make a change now the lawsuits will come (I do not know that there are any significant now state lawsuits that could be expanded). I agree with you, and I purchased, five years ago, before I knew about the problem.

Failures do occur, but all indications are that the frequency (at least For 2019+) is very low and the issues very likely can be almost always avoided but takes time (doing and reading) and effort, with potential failure still in the back of my mind. But woe to those who have a failure! I do not know if I would buy another under these conditions. If I was a just drive it and do almost nothing kind of guy, I would not buy one. I am not brand loyal. The gas trucks are looking pretty good for those who do not really really need a diesel.

Diesel fuel lubricity may have significantly improved over at least more recent years.

I would not buy a used truck of any brand with CP4, that was used, because you have no idea how pump wise it was taken care of.

I also do not understand how Ford has not lost CP4 lawsuits. I know money and lawyers but what are the details?

Added: If I was one of those with a failure my tune would change accordingly, not logical but it often is how we are wired.
 
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I also do not understand how Ford has not lost CP4 lawsuits. I know money and lawyers but what are the details?
Expensive lawyers will always win over regular people in a courtroom.
IMO...Ford has a long history of screwing people over. They screwed me over with a certain 2004 6.0L F250.
GM and Ram smartened up.
Current Ford owners just have to hope they aren't one of the lucky ones who get a trashed fuel system.
 
FWIW Ford's CP4 allegedly has an additional coating (teflon like) on the tappet and roller which were the failure points on RAM and GM. The amount of failures for each have never been disclosed but is perceived to be less than RAM (the highest) and GM (next). GM settled a class action for $35M mid-2024. RAM recalled their CP4s and replaced them with a modded CP3.

I sued GM once due to complete brake failure causing me to rear-end a tractor trailer. GM sent a team of five high powered attorneys from Minneapolis who only dealt with GM brake lawsuits. They weren't cheap I can guarantee you.
 
FWIW Ford's CP4 allegedly has an additional coating (teflon like) on the tappet and roller which were the failure points on RAM and GM. The amount of failures for each have never been disclosed but is perceived to be less than RAM (the highest) and GM (next). GM settled a class action for $35M mid-2024. RAM recalled their CP4s and replaced them with a modded CP3.

I sued GM once due to complete brake failure causing me to rear-end a tractor trailer. GM sent a team of five high powered attorneys from Minneapolis who only dealt with GM brake lawsuits. They weren't cheap I can guarantee you.
So now I gotta ask....how did you come out after suing GM?
 
FWIW Ford's CP4 allegedly has an additional coating (teflon like) on the tappet and roller which were the failure points on RAM and GM. The amount of failures for each have never been disclosed but is perceived to be less than RAM (the highest) and GM (next). GM settled a class action for $35M mid-2024. RAM recalled their CP4s and replaced them with a modded CP3.

I sued GM once due to complete brake failure causing me to rear-end a tractor trailer. GM sent a team of five high powered attorneys from Minneapolis who only dealt with GM brake lawsuits. They weren't cheap I can guarantee you.
CP4 affected parts were coated with Teflon around 2020-2021. Pressure was increased from 30ksi to 39ksi (per copilot) in 2020. Big change and how did that affect reliability? Should be more energy efficient and possibly better emissions. Sounds like it could be more heavily loaded (psi, unless roller contact area was increased, but see below reduction in load). Also does not sound like something a company would readily do if they were very fearful of excessive failures, they need to compete, or they are delusional.

News to me and huge (possibly was largest cause of failure): Bosch CP4 fuel pump has undergone some redesigns to address issues related to piston rotation. Specifically, the CP4.2 (mid 2020) variant introduced a symmetrical cam lobe and a keyway to prevent the roller bearing from rotating, which helps keep the piston properly oriented. This change was made to reduce the aggressive ramp rate of the cam lobe, which was believed to contribute to lifter failure in earlier versions.

Rotation was a key problem with the pump and Ford would not pay patent owner for a fix--if I remember correctly.

Failures still are occurring (less frequent?) with above design and with continued risk of trashing fuel system, cost to repair continues to rise with inflation.

Bosch CP3 is in range of 24 to 29ksi so even if it would fit in Ford (it doesn't) it may not be the best option.

It is hard to not feel Ford should be penalized by truck sales loss, very much extended warranty and recall cost.
 
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News to me and huge: Bosch CP4 fuel pump has undergone some redesigns to address issues related to piston rotation. Specifically, the CP4.2 (mid 2020) variant introduced a symmetrical cam lobe and a keyway to prevent the roller bearing from rotating, which helps keep the piston properly oriented. This change was made to reduce the aggressive ramp rate of the cam lobe, which was believed to contribute to lifter failure in earlier versions.

Rotation was a key problem with the pump and Ford would not pay patent owner for a fix--if I remember correctly.
The CP4.2 was failing on the RAMs as well (2019-2020). There were two versions of 4.2 on a RAM - early and late but both still failed - the piston would rotate 90 degrees and shards of metal would follow. Bosch claimed it was bad fuel, bio-diesel, running out of fuel, etc. I was really glad for the recall and replacement. Mileage went up (3mpg hwy no load), less DPF regens with trailer, easier starting, smoother shifting on the Aisin (there was also a flash for this). The Cummins replacement HPFP was CP-ISB21 which was built along the lines of the CP3 but with 20% higher fuel pressure than the 4.2.

Thats why I found this recall interesting because it was specifically aimed at Fords stored during Covid with bio-diesel deposits resulting. So what if you normally run bio-diesel on pre-Covid models (I've been to some fuel sites out west where there was no choice)?
 
We live in MN and its one of those states that mandate Bio Diesel. There are many states that now mandate bio and in our annual trip from MN to FL, there would be no way around using bio parts of the journey. One of the big selling points for the purchase of our '21 RAM was their move away from the CP4. It gets pretty old listening to Bosch blaming CP4 problems on low lubricity fuel or other US fuel related problems. In my opinion that's a design flaw where Bosch failed to understand customer demographics. They should have designed to the lowest common denominator.
 
@roegs01 As I mentioned above, my 2001 Cummins with a Bosch VP44 died while I was pulling horses. On my replacement VP44 there was a Bosch flyer that specifically said use of bio-diesel would void the warranty. The irritating thing about the CP4 is that they were used in VW and Audi diesels which had huge problems prior to 2010. I read some of the emails between Bosch and VW/Audi and the high rate of failures in the U.S. So Bosch's problems are legend.
 
Copilot says for all below, but is sometimes wrong: Currently, Minnesota is the only state in the U.S. that mandates a 20% biodiesel blend (B20) during certain months of the year. From April 15th to September 30th, diesel fuel sold in Minnesota must contain at least 20% biodiesel. During the rest of the year, the requirement is lower, with a minimum of 5% biodiesel (B5) from October to March

For the Bosch CP4 fuel pump, it's generally recommended to use low biodiesel blends. The safest option is B5 (5% biodiesel), which provides some of the lubricity benefits without the potential issues associated with higher blends. Some users also report success with B10 (10% biodiesel), but it's important to monitor your vehicle's performance and consult your manufacturer's guidelines.

Cummins High-Pressure Fuel Pumps (HPFP) typically produce pressures in the range 29,000 to 32,000 psi but it can go up to 35,000 psi (approximately 241 MPa) under certain conditions.

Tim: I thought any vehicle sitting for extended periods of time with at least B20 and possibly B10 was a problem. B5 is still considered standard diesel and does not need notification on fuel station pump.
 
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