The used market has been pretty hot for the last several years. Our old trucks are getting more popular every day! If you’re looking for a new-to-you 7.3, there’s a few things that are worth keeping an eye out for. We’ve compiled a list of what to look for drivetrain-wise, when searching for a new 7.3 Powerstroke (including the fixes associated with each). This list is not all-inclusive. It's only the most common issues and/or the most expensive to fix. 

 

Pro tip: when test-driving, do both a cold start and hot restart. Most 7.3 problems show up only in those two moments.

 

1. Camshaft Position Sensor (CPS) Failure

What to Look For: No tach movement during cranking, sudden stalls, no-start conditions.

Fix: Replace with updated Ford or International sensor (check the harness for damage too). Keep a spare CPS in the glovebox—failure is common and sudden. CPS is available HERE and the harness pigtail HERE

 

2. Exhaust Leaks, Turbo Up-pipes & Collector Joints

What to Look For: Soot around up-pipes, whistling/jet noises, slow spool, lower boost.

Fix: Install updated bellowed up-pipes (available from HERE for 1994-1999 and HERE for 1999.5-2003). Don’t just tighten clamps—stock crush donuts will only leak again.

 

3. UVCH (Under Valve Cover Harness) Issues

What to Look For: Intermittent misfire, rough starts, contribution/balance codes.

Fix: Replace the UVCH pigtails and clips (UVCH replacements available HERE for 1994-1997 and HERE for 1999-2003). If the connectors on the injectors themselves are burnt, you'll likely need to have them fixed by a professional or replace the injectors. 

 

4. Fuel Filter Housing Leaks 

What to Look For: Fuel seepage at seams on filter housing, or fuel in teh valley if really bad. Also check the filter drain valve on 1999-2003 models. These are very common leak items. You'll likely see a fuel puddle/drips under the truck.

Fix: Rebuild fuel bowl or replace if cracked (rebuild kits are available HERE for 1994-1997 and HERE for 1999-2003. Full new bowl's HERE for 1994-1997 and HERE for 1999-2003). Replace Fuel Bowl Drain Valve (new valves can be found HERE)

 

5. High-Pressure Oil Pump (HPOP) & IPR Issues

What to Look For: Oil leaks pooling in engine valley, hard hot starts, low ICP pressure codes.

Fix:

• Reseal with HPOP O-ring kit (available HERE).
• Replace IPR if leaking or sticking (very commonly, IPR issues are due to contamination and a cleaning will fix them).
• For bad pumps, use an OEM/Bosch or trusted aftermarket replacement (not eBay cheapies). HPOP for the 1994-1995 is available HERE. HPOP for the 1996-1997 is available HERE. And the 1999-2003 HPOP is HERE.

 

6. Oil Leaks in the Valley 

What to Look For: Oil puddling in the V of the engine, oil dripping down bellhousing visible where the transmission inspection plate is.

Fix: Identify source: HPOP o-rings, turbo pedestal o-rings, IPR, or fuel bowl. Reseal as needed. Clean valley afterward to track future leaks.

 

7. Smoke Issues

White Smoke on Startup: Usually glow plugs not working, tired injectors, or coolant entering the cylinders.

Fix: Replace bad glow plugs, relay, or module, harnesses are also common fail items (glow plugs are available HERE, relays HERE, and modules HERE) Replace injectors if they're tired/worn out (many different injectors can be found HERE). If coolant-related, check for injector cup leaks or head gasket failures.

Blue Smoke: Oil burning, typically from bad turbo seals or injector o-rings.

Fix: Rebuild turbo, replace injector o-rings. Turbo rebuild kit for the 1999-2003 can be found HERE. Many other turbo parts can be found on our website. Injector O-rings can be found HERE.

Black Smoke: Excess fuel/low boost.

Fix: Check up-pipes for leaks (see above mention). Check the intercooler boots for cracks, splits, or other failures. Make sure the air filter is clean. Last, check MAP hose and pigtail for failures (the sensors themselves rarely fail). Up pipes can be found HERE for 1999-2003 and HERE for 1994-1997. Intercooler boots can be found HERE for the 1999-2003. 

 

8. Exhaust Back Pressure Valve (EBPV)

What to Look For: Jet-engine sound, valve sticking closed, sluggish cold idle or (the most common) oil leak in the valley near turbo.

Fix:

Lube or rebuild actuator. Rebuild kits can be found HERE for 1999-2003 and HERE for 1994-1997. 

Many owners remove their EBPV altogether with a non-EBPV pedestal and outlet. Improves reliability, no real downside except less cold warm-up help. All those parts can be found on our website. 

 

9. Steering & Driveability

What to Look For: Death wobble, loose steering, rough idle at stoplights (very common).

Fix:

Replace worn ball joints, tie rods, track bar bushings.

Steering box play is common. Replace steering box.

For idle issues, clean IPR and ICP sensor (replace either, if necessary), and check UVCH connections (replace if damaged). Links to all these replacement parts are listed above in their respective sections.

 

10. Cooling System

What to Look For: Oil in coolant, sludge, leaking radiator end tanks.

Fix:

Replace radiator if plastic end tanks seep.

Flush cooling system, refill with ELC (extended-life coolant).

For oil contamination, inspect and replace the failed oil cooler (somewhat rare).

***Disclaimer: The information provided on this blog is for informational purposes only. We share our knowledge and experience, but we are not liable for any damages, injuries, or losses that may occur as a result of using this information. Situations are rarely cut and dry in the automotive world. Your situation will likely be somewhat different than what we describe here.  Use your best judgment and always consult a qualified professional for automotive repairs and modifications. Your safety is your responsibility.