If you own a Ford truck equipped with the 6.7L Powerstroke engine, there’s a hidden time bomb under your hood—the CP4 high-pressure fuel pump. This component is notorious for failing, often without warning, and causing damage so severe it can total your fuel system. At Bootlegger Industries in Oak Ridge, Tennessee, we’re here to help you prevent disaster with a trusted solution: the DCR conversion.
What Is a DCR Pump?
DCR stands for Diesel Common Rail—a type of fuel pump engineered for high-pressure diesel injection systems. In the context of 6.7L Powerstroke engines, the DCR pump is a two-piston, diesel common rail replacement pump designed by Stanadyne and offered exclusively through S&S Diesel Motorsport. It serves as a direct replacement for the problematic CP4 pump, known for its high failure rate.
Unlike the CP4, the DCR pump features a pressure-lubricated cam and bushings, a patented eccentric drive system, and enhanced durability in low-lubricity or biodiesel fuel environments. It provides all the performance benefits of the more reliable CP3 design but is uniquely engineered to install without ECM tuning while maintaining emissions compliance.
Understanding the DCR Conversion Kit
The S&S Diesel DCR kit replaces the faulty CP4 pump in your 6.7L Powerstroke engine with a more reliable and proven CP3-style pump. Designed specifically for Powerstroke applications, this conversion eliminates the most common failure point in your fuel system using a durable, mechanical, and well-lubricated pump design.
About the S&S Diesel DCR Kit
The S&S Diesel DCR Kit isn’t just a band-aid—it’s a comprehensive solution backed by some of the most respected names in diesel performance engineering. Here’s what makes it the best in the industry:
- No Tuning Required: This conversion requires no ECM tuning. It’s a drop-in replacement that uses factory lines and maintains OEM emissions compliance.
- OE Fit and Finish: The DCR kit includes a proprietary pump designed to match the footprint of the CP4, allowing for smooth installation with no major modifications.
- Prevents Catastrophic Fuel System Failure: The CP3-style design offers better internal lubrication and durability, minimizing the risk of failure.
- Trusted by Diesel Pros: S&S Diesel Motorsport components are known for reliability and innovation. Their DCR kit is precision-engineered and tested extensively.
- 50-State Legal: EPA compliant and CARB exempt, the DCR kit is legal for use in all 50 states.
Built for Durability
The DCR pump is internally lubricated with fuel and designed with improvements that overcome the poor tolerances and substandard metal quality of the CP4.
“All 6.7 Powerstrokes have a failure point, which is the high-pressure fuel pump, and this is one of the repairs that is the most common and most price effective,” Chris Slagle of Bootlegger Industries said.
What You Need to Know About the CP4 Pump Failure
What Is the CP4 Pump?
The CP4 is a high-pressure fuel injection pump manufactured by Bosch. It was introduced as a more compact and fuel-efficient replacement for the earlier CP3 pump. Ford began using the CP4 in 6.7L Powerstroke diesel engines starting in 2011 as part of a broader move to meet modern emissions standards and improve fuel economy.
Why the CP4 Pump Fails
However, the CP4 pump has significant flaws when used in U.S. diesel environments. Unlike its predecessor, the CP4 lacks sufficient internal lubrication and is extremely sensitive to even minimal amounts of fuel contamination.
When it goes, it goes hard—dumping metal shrapnel through your entire fuel system. That means new injectors, high- and low-pressure fuel lines, tank cleaning, and more. This is why the CP4 pump has gained a reputation as a high-risk component and why replacing it preemptively with a more robust solution—like the DCR conversion—can save truck owners thousands in repairs.
As Chris Slagle explains:
- “What normally happens is they start getting a little bit of contaminated fuel, and it literally rusts the buckets inside the pump, and it just disintegrates.”
CP4 Failure Warning Signs: Know the Symptoms Before It’s Too Late
Spotting the early signs of a failing CP4 pump can help you avoid catastrophic engine damage. Here’s a quick reference guide to help you act fast:
| Symptom | What It Might Mean | What You Should Do |
|---|---|---|
| Long crank or hard starting | Early stage fuel delivery issue or CP4 degradation | Schedule DCR conversion diagnostic |
| Rough idle or unusual engine vibration | CP4 internal wear or injector damage | Inspect fuel system and replace CP4 with DCR |
| Loss of power under acceleration | Fuel pump not maintaining pressure | Book DCR conversion to prevent full failure |
| Metal shavings in fuel filter | Imminent CP4 failure – metal in system | Replace pump immediately with DCR kit |
Fuel System Enhancements
A Preventative Investment or a $15,000 Nightmare
If you wait for the pump to fail, you’re likely looking at $14,000 to $16,000 in repairs. But if you act early and install a DCR conversion kit, the fix only costs $2,400 to $2,500—and you avoid all that downtime and stress.
Signs Your CP4 Pump Might Be Failing
Although CP4 failures often occur without warning, there are a few subtle symptoms drivers might notice:
- Hard starting or long crank times
- Loss of power or sluggish acceleration
- Rough idle or unusual engine vibration
- Check engine light or fuel system codes
- Metal shavings found during fuel filter inspection
“There’s really not that many signs. It just happens,” Slagle warns. “So people do it (DCR conversion) kind of as a precautionary replacement.”
Will It Void My Warranty?
Navigating Warranty Concerns
This is one of the biggest concerns truck owners have. Technically, yes—installing a DCR conversion does void your Ford warranty. However, many dealerships are now replacing these failed CP4 pumps free of charge.
- “If we can do a corrective issue that solves the problem, then that part of the equation—the 98 percent fail rate—that’s gone.” — Chris Slagle
It’s about weighing risks. Ford might cover the failure once, but a DCR conversion eliminates the issue entirely.
Who Should Consider a DCR Conversion?
Every 6.7L Powerstroke Owner
If you’re driving a 2011–2022 Ford Super Duty with a 6.7L Powerstroke engine, this concerns you. Whether you’re a weekend warrior, daily driver, or working your truck hard with fleet duties, you’re at risk.
Even just driving down the road can trigger a failure if the conditions are right. At Bootlegger Industries, we often recommend the DCR conversion for anyone looking to protect their investment and avoid catastrophic repairs.
Why Choose Bootlegger Industries for Your DCR Conversion?
Trusted Diesel Experts in Oak Ridge, TN
Bootlegger Industries was built on diesel expertise. Our roots go deep—starting with Chris Slagle wrenching on trucks as a teenager, to building a shop that serves fleet clients like FedEx, local fire departments, and law enforcement vehicles.
Here’s what sets us apart:
- Thorough diagnostics process for every truck
- Customer-first service that educates and empowers
- Fleet maintenance expertise
- Top-tier parts and trusted install techniques
- After-hours key drop and flexible pickup options
- Military and First Responder discounts
Our mission is simple: Renovation becomes necessity. That means we’re not just fixing your truck—we’re preventing future breakdowns before they start.
What to Expect During Your DCR Conversion
- Schedule a Diagnostic Visit
We’ll inspect your system to make sure a DCR conversion is right for your truck. - Install S&S Diesel DCR Kit
The only trusted CP4 replacement on the market. We use high-quality parts and meticulous install techniques. - Final Fuel System Inspection
We ensure your fuel lines and tank are free of contamination before buttoning everything up. - Backed by Warranty
Manufacturer warranties apply, and we offer a 60-90 day install warranty for peace of mind.
What Happens If You Don’t Replace the CP4?
A Real-World Scenario
Let’s break it down:
- Fuel pump fails
- Metal shavings enter fuel system
- All injectors are damaged
- High and low pressure lines must be replaced
- Fuel tank needs to be cleaned or replaced
- You’re without your truck for weeks
Now compare that to spending a fraction of the cost and one day in the shop for a DCR conversion.
Frequently Asked Questions About DCR Conversions
Will It Affect My Truck’s Performance?
Yes—in a good way. The CP3-style pump used in the DCR conversion delivers smoother fuel flow and is more reliable under pressure.
Is the DCR Kit Legal?
The kit from S&S Diesel is EPA compliant and designed for use on 50-state-legal trucks. It’s a direct upgrade, not a deletion or emission system bypass.
Protect Your Truck Before It’s Too Late
Don’t wait for disaster to strike. If you own a 6.7L Powerstroke, the DCR conversion is the smartest investment you can make to protect your engine, wallet, and peace of mind.
At Bootlegger Industries, we treat every diesel like it’s our own. Whether you’re local to Oak Ridge or driving in from Knoxville, we’re your go-to source for diesel expertise and honest, high-quality repairs.
Ready to Schedule Your DCR Conversion?
Call or text us today at 865-730-3156, request an appointment online, or visit us in person at 91 Midway Ln, Oak Ridge, TN 37830.
