Sounds similar to what I've been experiencing with my 2001 with the Cummins.
Expect, my filter isn't being sucked dry.
I've been finding out that Ford has had some fuel tank issues.
I'm wondering if what you're experiencing with your CAT is on the same page what I've been experiencing with my Cummins?
Everytime my fuel line/system is cracked into, it runs good for a week or two, as well. Infact, about 1 month after the dealer worked on the truck, it started acting up. I called the dealer and practically called them every name in the book. I then replaced the fuel filter, and it ran like a brand new truck! Then, I felt like a fool for being such a jerk to them, I was thinking "here I acted like that and all it was, was a dirty fuel filter". Well......after the filter replacement, it only ran great for 2 weeks, then started acted up all over again.
I'm thinking that what's happening is when the line is opened, the dirt on the screen of the sending unit is dropping off, then taking 1-2 weeks to build up on the screen.
Here's a link to my issue:
2001 F-650 With erratic throttle
Also after a comprehensive GOOGLE search I found this on the net. It's small print, but you cann see where his 2004 F650 had to have the tanks replaced. Based on the date of his letter, and the date he mentioned buying the truck.....he had to replace the tanks when it was EIGHT MONTHS OLD!
"The Anti-Ford Page: Consumer Letter"
Even if they're not similar, I'd be interested in hearing what you find is wrong. So please post your findings!