Ford 7.3-Liter Energy Stroke: Years to Keep away from for Dodging Pitfalls

For many years, the Energy Stroke household of diesel engines has carried out obligation in a number of Ford pickup vans. The primary engine to bear the Energy Stroke title was the 7.3-liter turbodiesel V8 launched in 1994, a revolutionary engine with spectacular applied sciences for the time resembling direct injection. Whereas the mill has a typically wonderful fame for reliability, it is not with out its flaws. Right here, we’ll cowl the years to keep away from for the 7.3-liter Energy Stroke engine, in addition to the frequent issues to look out for if you happen to personal or plan to purchase a pickup with considered one of these engines. It was fitted to Tremendous Obligation Ford vans just like the F-250 and F-350 till it was discontinued because of being unable to fulfill new rules.

Manufactured by Navistar Worldwide Company, the 7.3L diesel V8 is often known as the Navistar T444E. It went into manufacturing in 1994 and was initially used within the Ford F-250 and F-350. It additionally discovered its means into the Ford E-Sequence line of full-size vans and the Ford Tour within the early 2000s.

With a bore and stroke of 4.11 in. by 4.18 in., the 7.3L Energy Stroke initially made 210 horsepower and 425 lb-ft of torque. Energy and torque steadily elevated by way of the years, culminating in outputs of 275 hp and 525 lb-ft when outfitted with a guide transmission.

This engine options electronically managed, direct injection. Initially, a single turbocharger with a non-wastegate design was used. Early Energy Stroke engines had “single shot” HEUI (hydraulically actuated digital unit injection) gasoline injectors. By comparability, extra trendy common-rail injectors carry out 5 or extra injection occasions per combustion cycle, making them susceptible to accelerated put on.

A wastegate was added halfway by way of the 1999 mannequin yr, together with bigger injectors. Across the similar time, an air-to-air intercooler was one other improve. Catalytic converters had been solely put in late within the engine’s life. It is partly as a result of this engine might be designed with out regard for stringent emission controls, making it less complicated, that it’s so extremely regarded for dependability. For instance, the 6.0-liter Energy Stroke that changed this engine had an exhaust fuel recirculation system that launched an entire new vary of points.

Due to its incapability to fulfill California noise rules, the 7.3L Energy Stroke was discontinued early within the 2003 mannequin yr and changed by the 6.0-liter PowerStroke.

Usually, this engine has a stable fame for reliability and may final for over half one million miles if correctly maintained. Nevertheless, there are a number of mannequin years which can be higher to keep away from if you would like one of the best probability of getting a used truck with a trouble-free engine.

From the 2001 mannequin yr, the solid connecting rods that had been used for the sooner Energy Stroke engines had been changed by much less strong powdered metallic rods (PMR). The PMRs had been superb for unmodified engines, however tuned engines that pushed the output over round 450 hp usually resulted in a catastrophic failure of the PMRs. The Energy Stroke engine was standard with tuners, with many including an upgraded turbocharger to spice up its moderately modest inventory outputs.

Additional complicating issues is that not all of those newer Energy Strokes had the PMRs. The solid-steel rods had been reintroduced for some engines to do away with the remaining stock, so it is not instantly apparent which of them you are getting with the newer PowerStroke-equipped vans.

Utilizing a boroscope, one can view the serial numbers to determine which Energy Stroke had the solid connecting rods and which had the PMRs. Based on 73psd, these are the serial numbers for engines with both solid rods or PMRs:

For those who plan on modifying your Energy Stroke or are buying a modified model, we suggest staying away from the PMRs. 2001-2003 fashions had been additionally susceptible to points with the exhaust, in addition to excessive engine noise associated to the split-shot injectors.

Whereas we would not go as far as to say it’s best to fully ignore these mannequin years of Ford vans with the Energy Stroke engine, there are a number of causes to think about the 1999 mannequin yr as an alternative.

Not solely are the 1994-1998 engines the oldest, however additionally they produce the least horsepower of the Energy Stroke 7.3-liter household. This will frustrate in each day driving, however should not be a significant difficulty if all you need is a fundamental workhorse. In 1998, for the 1999 mannequin yr, outputs elevated from 210 hp/425 lb-ft to 235 hp/500 lb-ft.

Apart from the change to powdered metallic rods lined above, there are one other few frequent points to all of those Energy Stroke engines which can be price understanding about, together with quite a few poor electrical connections.

A worn or failing CPS may cause the automobile to stall whereas driving or not begin up in any respect. If the tachometer would not transfer when cranking, the CPS is probably going performing up or in want of substitute. Happily, a brand new one is not prohibitively costly, with an OEM CPS for the Energy Stroke listed for $33.95 on ProSource Diesel.

UVCH connectors with these engines are susceptible to loosening or shorting out, which disrupts contact with the injectors or glow plugs. You’ll be able to discover this if the engine runs tough otherwise you expertise engine-loping, sputtering, or the V8 merely dying fully.

1994 to 1997 Energy Stroke engines had two connectors main into every financial institution, whereas later engines had only one connector. It was simpler to troubleshoot the precise difficulty with the harness on the sooner engines. For the reason that connectors are under the valve cowl, it is sensible to switch the valve cowl gaskets on the similar time.

As soon as once more, this can be a moderately inexpensive job.

This can be a butterfly valve discovered on the turbocharger, with its predominant job being to decrease the time that the engine must return to its regular temperature. This valve can typically shut and get caught, resulting in sizzling exhaust air build up within the engine. A jet engine-like noise from the exhaust is one signal that that is taking place.

The turbocharger up-pipes of the Energy Stroke can leak from numerous factors, however particularly on the joints. If this occurs, the engine will lose increase and exhaust fuel temperatures will rise. A ticking noise by way of the firewall and plenty of black smoke are two signs, as is a lack of energy.

The IDM is liable for switching the injectors on and off, based mostly on instructions from the Powertrain Management Module (PCM). Nevertheless, this half can develop into contaminated with water, resulting in failure. A tough idle or the shortcoming to start out the truck might be indicators of this drawback.

This valve can typically stick, and since its job is to regulate the oil strain within the engine, that is a difficulty. A rough-running engine, a sudden stall, or not having the ability to begin the automobile are all indicators of this drawback. The engine can usually crank however will not begin when this valve malfunctions.

Round two million 7.3-liter Energy Stroke turbodiesel engines had been made, and for good purpose. This unit has a well-earned fame for reliability, and most of the points affecting it may be repaired with out breaking the financial institution. It gave Ford a stable different to the Cummins B-Sequence energy plant from Dodge and the Duramax V8 from Common Motors. Though there are a number of extra troublesome mannequin years, each model of the Energy Stroke has an excellent probability of racking up over 250,000 miles – and rather more than that in some circumstances – earlier than a significant restore is required.