Not all injection pumps are built to survive real-world diesel demands, and Powerstroke owners are starting to take notice. The CP4 may have come factory-installed, but its failure rate has led many to search for a smarter solution. Enter the DCR. At Archie & Sons Diesel Repair, we’ve seen firsthand how this upgrade can mean the difference between costly downtime and long-term reliability. But is it the right move for your truck? Let’s break it down.
How the CP4 Became a Problem Child
The CP4 pump, introduced with the 2011 6.7L Powerstroke, was meant to deliver on modern emissions regulations. It does its job efficiently until it doesn’t.
The problem? The CP4 pump wasn’t designed with American diesel fuel quality in mind. It has extremely tight tolerances and lacks the internal lubrication needed to handle any fuel inconsistency. When it fails (and unfortunately, it often does), it sends metal shavings into your entire fuel system, contaminating injectors, fuel rails, and lines. This leads to complete system failure, often requiring a full replacement.
It’s a well-documented issue. CP4 injection pump failure is one of the most searched concerns among Powerstroke owners. Lawsuits and recalls have popped up due to the widespread nature of this problem.
If your CP4 pump fails, repair costs can easily climb past $10,000, especially if your truck is your primary workhorse.
Meet the DCR Pump: A Smarter Solution
The DCR, S&S Diesel Motorsports’ answer to the CP4’s shortcomings, is used in newer Powerstroke models (2010 and up). The DCR offers improved reliability, smarter fuel pressure control, and less risk of catastrophic failure.
The DCR pump is based on a compact and modular design for easy integration, has low hydraulic and acoustical noise, features ultra-fast response times, and is biofuel and low-lubricity fuel compatible. It uses a patented eccentric drive pumping technology, with pressure-lubricated cam and bushings, for increased performance, efficiency, and benchmark durability. That means:
- Better response under load
- Reduced fuel system stress
- Quieter operation and smoother idling
- A design that handles poor fuel quality more effectively
Most importantly, the DCR pump is built with better internal lubrication and materials, reducing the chance of fuel system contamination even if something does go wrong.
CP4 Injection Pump Failure: The Costly Chain Reaction in Powerstroke Diesels
Let’s take a deeper look at what happens to your entire system when the CP4 fails:
- The high-pressure pump shreds itself internally
- Metal particles flow through the lines into your injectors
- Your truck may shut down suddenly or experience major power loss
- Even your fuel tank may require cleaning or replacement
The worst part? Many truck owners don’t realize the extent of the damage until the second failure, or the third, because the system was never fully flushed or replaced after the first pump gave out.
If you’ve already replaced a CP4 once, you may be sitting on a ticking time bomb.
DCR vs CP4 – Side-by-Side Comparison
Summer maintenance doesn’t need to be complicated, but it needs to be consistent. Here’s a breakdown of what every diesel owner should inspect before peak heat season hits.
| Feature | CP4 Injection Pump | DCR Injection Pump |
|---|---|---|
| Lubrication | Poor | Excellent |
| Failure Risk | High | Low |
| Common Result of Failure | System-wide contamination | Localized, minimal risk |
| Pressure Regulation | Mechanical | Electronic |
| Fuel Tolerance | Low (sensitive to quality) | Moderate (handles real-world fuel) |
| Retrofit for Older Trucks | Requires kit | Compatible with most 6.7L models |
| Maintenance Cost | High over time | Lower long-term investment |
| Best Use Case | Short-term, light-duty use | Fleet, heavy-duty, long-haul diesel use |
Why Powerstroke Diesel Owners in NC Choose the DCR Pump Upgrade
Whether you’re a contractor towing heavy equipment or just someone who needs their truck to fire up every morning without issue, reliability isn’t optional. And since CP4 failures don’t always show signs until it’s too late, many drivers are opting to upgrade before disaster strikes.
For trucks used in fleet settings around Kenly and Benson, this switch is especially important. Downtime means lost revenue, missed appointments, and frustrated clients.
Schedule your service now to discuss DCR conversion options with our team.
Let’s Talk Torque: How the Right Pump Enhances Performance
What most don’t realize is that the DCR pump doesn’t just protect your truck; it can also improve how it runs. If you’ve noticed lag when towing through the backroads of Fremont or power loss under load near Nashville, you might be feeling the limits of your CP4.
Here’s what Powerstroke owners report after a DCR upgrade:
- Improved low-end torque
- Faster cold starts
- More consistent throttle response
- Better support for tuning and performance modifications
It’s not about pushing massive horsepower gains. It’s about unlocking the engine’s full potential safely and reliably.
A Shop That Knows Powerstroke Inside and Out
At Archie & Sons Diesel Repair, we help Powerstroke owners make smart, long-term upgrades that boost reliability and performance. Serving drivers and fleets across Johnston County, from Raleigh and Goldsboro to Smithfield, Kenly, and beyond, we’re trusted by those who rely on their trucks every day.
Here’s what sets us apart:
- OEM dealer scan tools and high-end diagnostics
- Technicians who specialize in domestic and diesel vehicles
- Transparent estimates with no pressure
- Fleet-focused maintenance and repair solutions
- Backed by a 2-year/unlimited mile labor warranty and 2-year/100,000-mile powertrain coverage
We’ve replaced countless failed CP4 pumps and have seen the costly damage they leave behind. That’s why we confidently recommend DCR conversions for Powerstroke owners who want peace of mind.
Book an appointment online and protect your Powerstroke from unexpected downtime.
Let’s Not Forget the Bigger Picture: Maintenance Still Matters
Upgrading to a DCR pump isn’t a set-it-and-forget-it solution. Like any precision component in your Powerstroke diesel, it still requires clean fuel, regular maintenance, and a proactive approach to keep it performing at its best. At Archie & Sons Diesel Repair, we support your investment with complete fuel system service plans that include top-tier OEM filters, high-quality diesel fluids such as Rotella and AMSOIL, and advanced diagnostics to detect issues before they escalate.
For fleet owners and business operators in areas like Raleigh or Goldsboro, we also offer preventive maintenance schedules tailored to your operation, designed to minimize unexpected downtime and maximize the lifespan of your vehicles.
Frequently Asked Questions
Does upgrading to a DCR pump void my factory warranty?
If your vehicle is still under the original manufacturer’s powertrain warranty, any modification, including a DCR conversion, could potentially impact warranty coverage. However, for most 6.7L Powerstroke trucks eligible for the DCR upgrade, the factory warranty has already expired. We recommend consulting your warranty documentation or speaking with a Ford dealer for specifics.
How long does a DCR pump installation typically take?
A standard DCR conversion usually takes 6 to 8 hours, depending on the condition of your current fuel system and whether additional components (like injectors or filters) need replacement. We always perform a full inspection before starting to ensure you get a complete and efficient service.
Can I run biodiesel with a DCR pump?
While the DCR pump is more tolerant of variable fuel quality than the CP4, it’s still best to stick with OEM-approved diesel fuel (B5 or lower). Higher blends of biodiesel can still increase wear and may not be covered by warranties or parts manufacturers.
Will a DCR upgrade improve my fuel economy?
Fuel economy gains vary, but many drivers notice modest improvements in MPG, particularly under load or during highway driving. The more consistent fuel delivery and smarter pressure regulation contribute to better combustion efficiency.
Do I need to reprogram my ECM after installing a DCR pump?
DCR conversion kits require the fuel system learned values to be reset, as the DCR does have 25% more displacement than the factory CP4. At Archie & Sons Diesel Repair, we handle all required parameter resets and programming as part of your installation.
What’s the Best Pump for Your Powerstroke?
If you’re still wondering whether to upgrade your CP4, here’s the bottom line:
- CP4 injection pump failures are common, costly, and often unavoidable
- The DCR pump is more reliable, better engineered, and already standard in newer models
- A DCR conversion can be one of the most valuable Powerstroke fuel system upgrades available today
Don’t wait for a breakdown on the job or during your next trip through Johnston County. Make the upgrade before you’re left with a four-figure repair bill and a truck out of commission.
Ready to Upgrade? Let’s Get Started
If you’re ready to upgrade your Powerstroke with confidence, Archie & Sons Diesel Repair is here to help. Backed by dealer-grade diagnostics, expert technicians, and a commitment to doing right by our customers, we serve hardworking truck owners throughout Johnston County and surrounding areas. Whether you’re coming from Fremont, Raleigh, or Nashville, you’ll get the transparency, honesty, and skill your truck deserves.
Give us a call at (919) 221-0008, or stop by our shop at 2379 US-13 Goldsboro, NC 27534. Want to save time? Request your appointment online today and let us help you protect your investment the right way.
