S&S Diesel Motorsport CP4 Disaster Prevention Kit (2011-2025 6.7L Ford PowerStroke)

Fitment

Fits 2011 to 2025 Ford Super Duty pickup trucks with the 6.7 Power Stroke diesel engine: the F-250 and F-350 Super Duty and the F-450 pickup. That covers both the 2011-2016 and the 2017-and-newer 6.7L, and there is no longer a need to sort kits by the year the truck was made. Our listing uses the 2011-2025 range from the title, so verify fitment by VIN on a 2026 truck or a chassis cab before you order. More fuel system parts for your engine are in our Power Stroke section.

If your truck already runs the S&S DCR Pump Conversion, you don't need this kit: S&S says the DCR is not compatible with, and does not need, the Disaster Prevention Kit. If you already own an earlier S&S kit, look at the two upgrade options under What you get.

Why this part

Every 6.7L since 2011 uses the Bosch CP4.2 high-pressure pump, and it is lubricated by the fuel it moves. Aerated or low-lubricity fuel can let it wear and shed metal through the rails, injectors and return, with no fixed failure mileage. Symptoms include hard or long cranking, P0087 low rail pressure, sudden power loss and metallic glitter in the fuel filter. Once that metal is loose the repair is rarely pump-only: the pump, all eight injectors and every fuel line get replaced and the tank is pulled and cleaned, and dealer bills can exceed $10,000.

The kit's main task is to supply the CP4 case and the metering unit/plungers independently with clean, filtered fuel, and to reroute case fuel back to the tank. If the pump fails, the debris leaving the pump case goes into the return circuit, where a filter isolates it, instead of on to the injectors. S&S also notes the kit can extend the range of a truck during a CP4 failure.

S&S Diesel Motorsport created the original Disaster Prevention Kit for the 6.7 Power Stroke. Since its debut in 2016 it has safeguarded thousands of injectors from CP4 debris, and it worked well enough that multiple companies in the aftermarket copied it. S&S was founded by fuel system engineers, and the four years after that first kit gave them time to discover and eliminate its potential problems. Gen2.1 makes two major improvements.

Supply split 25 inches from the pump. The Gen2.1 fuel supply splits into two separate lines 25 inches away from the CP4. That eliminates the chance of contaminated case fuel back-feeding into the clean fuel supply line. The original kit split off within an inch of the pump and was more susceptible to back-feeding if a failure produced enough debris to clog the fuel return system.

A filter on the return. A billet return filter head takes a readily available Donaldson P550943 spin-on fuel filter (9-micron at 99% efficiency), which keeps debris from reaching the tank, fuel lines and supply pump. With the original kit, owners who lost a CP4 still had to drop the tank and deal with all of the debris the failed pump created.

What you get

This listing has three options. Pick the one that matches what is on your truck now:

• CP4-6.7F-BP-G2.1: the complete Gen2.1 6.7L Power Stroke CP4 Disaster Prevention Kit for 2011-2025 trucks, with all OE-style quick connect lines, the Gen2.1 billet return filter head and a Donaldson P550943 fuel filter.
• CP4-6.7F-BP-G2.1-RFA: the Gen2.1 Fuel Return Filter Assembly on its own, for owners of a first-generation Disaster Prevention Kit who want better debris management.
• CP4-6.7F-BP-G2.1-FHU: the Gen2.1 Filter Head Upgrade, which brings an existing Gen2 CP4 Disaster Prevention Kit up to Gen2.1 spec.

Specifications

• New and improved Gen2.1 Disaster Prevention Kit
• Safeguards fuel injectors, rails, lines, and tank from CP4 debris
• Thoroughly validated and proven to work in real-world testing
• All OE-style quick connects (easy install)
• Fuel supply split-off 25 inches away from the CP4 pump
• Return filter isolates CP4 debris before it goes on to the tank
• Gen2.1 billet filter head accepts standard spin-on fuel filters
• Comes with Donaldson P550943 fuel filter (9-micron at 99% efficiency)
• One part number fits all years (2011-2025)
• Improves CP4 output past 3,000 RPM
• Can extend the range of a truck during a CP4 failure
• CARB Compliant (EO# D-756-6)
• Made in the USA

Installation notes

Every line in the Gen2.1 kit uses OE-style quick connects, so you don't cut the factory supply line. A cut line is a place for debris to get in, especially if the cut isn't thoroughly deburred. The kit also does away with the compression fitting, a potential leak point, and with threaded joints that can leak or generate debris during install.

The Gen2.1 return filter head uses the same quick connect fittings and mounting hardware as the previous Gen2 filter, which is what makes the Filter Head Upgrade an easy retrofit. When the return filter is due, the Donaldson P550943 replacement costs less than the old Gen2 filters and most auto parts stores carry it. After any fuel system service, cycle the key 5-10 times, 20-30 seconds each, to prime the system before you crank the engine.

About S&S Diesel Motorsport

S&S Diesel Motorsport focuses on the high-pressure side of common-rail diesels, with injectors, CP3 pumps, CP3 conversion kits and CP4 solutions for Cummins, Duramax and Power Stroke trucks. For the 2011-and-newer 6.7L Ford it offers this kit, the DCR Pump Conversion and a Fuel Leak Prevention Kit. Shop the line on our S&S Diesel Motorsport page.

Frequently asked questions

Which option do I need?

No S&S kit on the truck yet: order the full kit, CP4-6.7F-BP-G2.1. Running a first-generation Disaster Prevention Kit: add the Fuel Return Filter Assembly, CP4-6.7F-BP-G2.1-RFA. Running a Gen2 kit: the Filter Head Upgrade, CP4-6.7F-BP-G2.1-FHU, brings it to Gen2.1 spec.

Does this kit stop the CP4 from failing?

No. It manages what happens when the pump fails, so the debris stays out of your injectors, rails, lines and tank. To cut wear on the pump itself, run a lubricity additive at every fill and don't run the tank low, since the CP4 is lubricated by fuel. If you want the CP4 gone entirely, look at the S&S DCR Pump Conversion instead; the two are not used together.

Is it legal on a street truck?

Yes. The Gen2.1 kit is CARB compliant under EO# D-756-6, and it is made in the USA.

Questions on fitment? Call the shop at the number in the header. We install everything we sell.