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Fixing Common 7.3 Powerstroke Problems

7.3 Powerstroke Problems

Believe it or not, the legendary 7.3 Powerstroke diesel engine is not problem free.

Common 7.3 Powerstroke problems can develop over the course of its lifecycle and those hundreds of thousands of miles.

Here are the most common 7.3 problems, how to spot them, and how-to articles on fixing them.

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7.3 Powerstroke Problems are Un common

Like a gritty old hunting dog that just won’t quit, your 7.3 Powerstroke diesel engine has officially become a legend. But despite being called the “best Powerstroke Ford ever built” and over 15 years since the last 7.3 left the production line, 7.3 Powerstroke problems are not as uncommon as you’ve been led to believe.

But the good news is, that as common as 7.3 Powerstroke problems are, most of the fixes for them are pretty straight forward.

Time, tools, and some tenacity go a long way in DIY repairing your 7.3 diesel’s most common problems. You bring those and we’ll show you where to point them…

Top 10 7.3 Powerstroke Common Problems

7.3 powerstroke common problem #1 – 7.3 cps–camshaft position sensor.

The failure of this sensor would create a no start condition or would shut the truck off as you were driving. An easy way to diagnose a failed CPS is to check for tach movement when you crank the engine over. If the tachometer doesn’t move, the CPS is probably bad.**

**Careful though, because after 2001 Ford changed the way the tach received electrical signal and this is no longer a reliable method to troubleshoot the CPS. Read this article for details on 7.3 CPS troubleshooting and replacement.

Read the 7.3 CPS article – 7.3 CPS-Cam Position Sensor

7.3 powerstroke common problem #2 – 7.3 fuel bowl – fuel filter/water separator.

The filter housing develops cracks in the aluminum housing and leaks fuel. The heating element inside the fuel bowl filter housing can short out, blowing a fuse and causing no start. And the o-rings on the fuel filter drain lever on the back of the fuel bowl assembly would corrode and leak.

7.3 Powerstroke Common Problem #3 – Leaking turbocharger up-pipes

The pipes can leak from many points but most commonly at the joints. Leaking of the up-pipes causes the engine to lose power and for exhaust gas temps–EGTs–to increase.

7.3 Powerstroke Common Problem #4 – EBPV failure.

Aged Exhaust Back Pressure Valves would open up in cold weather and stick on. This would cause a loud whining, “jet-engine” noise to come from the exhaust.

7.3 Powerstroke Common Problem #5 – Fraying and/or melted electrical wiring

Many 7.3 common problems were due to worn, fraying, and/or melted wires. The under valve cover harness–UVCH–would stop communicating with the glow plugs or injectors. This would cause rough starting and/or misfires.

7.3 Powerstroke Common Problem #6 – Valvetrain

7.3 Powerstroke valve springs didn’t have a high seat pressure. This led to valve float at high RPM’s sometimes causing bent or broken pushrods. Aftermarket springs and shims are available to solve the problem.

7.3 Powerstroke Common Problem #7 – IPR

Injection Pressure Regulator is a valve on the 7.3 high pressure oil pump. It can stick, get leaking o-rings, fail, or have a faulty connector. Read this article for more detail on troubleshooting and fixing the 7.3 IPR.

Read the 7.3 IPR article – 7.3 IPR – Injection Pressure Regulator

7.3 powerstroke common problem #8 – overheated engine.

Several things can cause your 7.3 to overheat. Rusted thermostat, worn or perforated radiator, a failed 7.3 water pump, running the wrong or bad coolant, and/or a broken engine cooling fan.

Read DHD’s 7.3 Water Pump Leak Article – Fixing a 7.3 Water Pump Leak

7.3 powerstroke common problem #9 – fuel bowl heater.

The 7.3 fuel bowl heater element sits at the bottom of the fuel bowl. A common problem with it, especially as your Powerstroke ages, is that it can blow the maxi fuse and/or fail or short itself out. When that happens it disables the PCM–Powertrain Control Module.

7.3 Powerstroke Common Problem #10 – ICP

A 7.3 Injection Control Pressure sensor–ICP–sensor failure, will make your diesel engine run rough . You can check to see if the 7.3 ICP is causing that rough running by unplugging it.

The PCM will then use default settings for the ICP and the rough running should go away.

Read DHD’s 7.3 ICP Article – 7.3 ICP – Injection Control Pressure Sensor

Fixes for other common 7.3 problems.

Click for a list of all of our 7.3 Powerstroke maintenance, repair, and information articles .

I'm Steve. I've owned over a dozen diesel pickup trucks in my life and always worked on them myself. I'm the owner of Dead Head Diesel. I live in California. You know, the diesel "friendly" state.

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My 7.3l is throwing a P0683 Code? Anyone had this problem?

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Thanks for your help. Just let me know what you did to fix or call me at 770-294-7663. Thanks, Randy  

Cool_Canuck

P0683 — GPCM GPCM glow plug control module communication line failure Open/shorted circuit, failed GPCM, failed PCM  

Soooo? Do you know what the fix could be? I just put a new PCM in this truck because the guy I bought it from had double chipped the motor and ruined the old pcm. But I can't get the truck to start either. It just keeps turning over. I have a new Cam Position sensor in it. New batteries, starter, and altenator. It was running very ruff before. Sometime the truck would just randomly cut off and then you would have to pull over and crank it. But it would continue to run like crap. I was going to look into chaning the wire harness to the aftermarket one. I heard sometimes this is the problem. Randy  

You don't give much information about your truck. I can assume from the code, it is a California truck or a Excursion. That code is telling you there is a problem with the glow plug controller and that is probably the reason the truck won't start. However, that is not a reason for the truck to run rough.  

Yup, details on the truck would be useful...where are you located? What's the temperature out there? P0683, as Canuck notes, is for California emissions or an Excursion (which came with CA emissions). It refers to the unique-to-Cali GPCM (versus standard-ole relays for the Federal-49). You said you replaced the PCM; is it possible you replaced it with a Federal-49 version instead of Cali? Got the old PCM available to see if it'll fire up on it?  

Im in Georgia and it's like 50F here. I do have the old pcm and could put it in. I bought it used so I would have to call the guy that I bought it from to see if it was from California. Where is the Glow Plug Module located? Is there a review anywhere to replace this part? I went ahead and bought one threw Ford. Randy  

It's a bright aluminum, finned unit, looks like this. If you paid less than $200 you got the wrong part: http://www.gatm.com/temp/DSCN4414a.JPG It's the item in the background; the relay in the foreground is the IAH relay...  

No. I bought the glow plug relay. The unit has two positive and two negative terminals on it. I don't think it is the problem though. Even though it is throwing that scan code. Randy  

Randy, you're missing the point(s): Point 1: Code P0683 is exclusively for a California-spec truck. Point 2: California-spec trucks use the aluminum, finned Glow Plug Controller Module as shown in the above photo, *not* the glow plug relay like the rest of the country (and Guzzle's descriptions). Ergo, if you are getting code P0683, and you do NOT have that above GPCM in your truck, it means one of two things: One, you have a Cali-spec truck and someone jury-rigged your truck to use a $25 Federal-spec GP relay instead of the $200 Cali-spec GPCM. In this case you can probably get the GPs to work using basic electrical troubleshooting, but you'll never get rid of the P0683 code 'cause your ECU can't find the requisite GPCM, or Two, you have a Federal-spec truck and you installed a Cali-spec ECU. That code will never go away because your ECU can't communicate with the GPCM... If you DO have the above aluminum finned relay, and your truck IS a Cali-spec, then the $25 GP relay you bought from the parts store is useless to you. Return it and troubleshoot the problems with the GPCM, likely either a failed GPCM or a problem with the wiring and/or plugs to the GPCM an/or the glow plugs. - GA  

Ohh sorry. I understand now. Yea I have a federal spec truck with a cali pcm I think. Thanks for that clearification. Sorry for my stupidity LoL. I had purchased this pcm used because my last pcm was no good. Thanks, Randy  

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02 7.3 PCM not responding

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currently working on a 2002 f250 with a 7.3 in it. customer was driving down the road and truck shut off and will not start since, crank but no start. has edge evolution installed in it and chip says pcm not responding, so unplugged that and hooked up scan tool and still no pcm connection. so made sure there was power to the pcm and also checked ground had both, fuses and relays are all good as well. so we checked idm and that checked out as well. just for fun we tried different pcm and idm off of another truck still no start but our pcm and idm ran the other pickup just fine. so we have been chasing wires all day to see if we could find short or anything of that nature and nothing came up there either.... a bit lost on what to look for now  

toolmangary

No communication with the PCM usually = the PCM has no power. Does the data link have power? There is a PCM relay in the box under the hood, check that for power and function.  

Yes it has power at data link and checked all the fuses and relays and those are all good as well  

Make sure there's continuty (sp) between obd port and pcm on data line.  

Ok, you swapped your PCM and IDM and you now that stuff is good, Do you know for sure which relay is for the PCM? and you swapped it? Are there any dead fuses in the fuse boxes? See if you have any dead wires on the ignition switch. with the key on I think all of them should be hot, no grounds go though it. What codes do you get? Maybe try I different scanner and pull the tuner off the truck  

I have tried using two scan tools and I get the same response that it cannot connect with the PCM so I can't access any codes and because I can't connect with the PCM it also will not let me uninstall the tuner. Going to check the ignition switch power again just to be sure. As far as the fuses there are no dead fuses at all in the fuse box and tried two brand new relays. We also tried new fuses for the fuses that control PCM power because we heard sometimes they will show power across the fuse sometime but they have to high of resistance and don't let high enough voltage go to the PCM but that didn't help the problem either.  

Ok, you must have a open circuit/broken wire somewhere, your going to need a wiring diagram, then and start checking each wire starting from the data link. That's what I would try.  

data_engine

^^^^ Yep that should do it, I'd start with checking the wire between the data link and PCM.  

Was there ever a solution to this issue I have the same problem occurring right now. I am lost. Thanks in advance  

I'm having the same issue crank no start glow plug light stays on longer than usual and I can't figure it out  

It is a common problem to have fuel bowl heater short and blow the fuse, which is the same one that supplies power to the pcm. If no wait to start light then check the fuse. I think it's the #30. You can unplug the fuel bowl heater and run without out it. Sent from my iPhone using Tapatalk  

BigRed02

Is a bad fuse block a possibility? I think there is 2 circuits for the PCM, right?  

Brian93

I have a similar issue with mone. I have no power to the fuel pump no communication with my pcm. No bad fuses or relays on my mine. See if you have any of the same issues  

I hope so I have the same problem with my truck  

I have been fighting the same (or very similar issue) hope someone here can help out. Truck ('02 Excursion 7.3) dies with no warning. Cranks with no start afterward. Passive anti-theft light flashes fast, then goes to the 1-6 code which is no communication with the pcm. First time it happened unfortunately I was 2 hours from home and had to have it towed to nearest ford dealer. Their only fix was to replace the PCM. 6 weeks later i pick it up and drive it home. After about 3-4 hours trouble free driving same issue repeats. This time I have it towed to a local diesel shop that specialized in powerstrokes. They find no power to the PCM, and diagnose the fuse block as bad. Replace, pay $900 and I am on my way confident that root cause was found. Drive another 2 days and same problem repeats. It is now back at the same diesel shop. Any thought from the forum?  

I am having the same problem with my 2001 F350 7.3 it just died on me will not start, wait to start light does not come on and I hooked 3 different code readers to it and all said negative or no response from PCM, I checked all fuses and relays and everything is good I'm getting power to the OBD2 port but no response from the ECU the truck will run if you spray ether but when you quit spraying it it will die it's like the computer is not telling the injectors to fire can somebody please please please help me with this I don't know what it would be my email is [email protected] if anybody has found the solution for this problem please email me  

Cody420169 said: I am having the same problem with my 2001 F350 7.3 it just died on me will not start, wait to start light does not come on and I hooked 3 different code readers to it and all said negative or no response from PCM, I checked all fuses and relays and everything is good I'm getting power to the OBD2 port but no response from the ECU the truck will run if you spray ether but when you quit spraying it it will die it's like the computer is not telling the injectors to fire can somebody please please please help me with this I don't know what it would be my email is [email protected] if anybody has found the solution for this problem please email me Click to expand...

I had this happen on my 2000. Somehow the EBV sensor spazzed out, it was suggested to me to try unplugging it and sure enough PCM back online and could read the truck to see nothing else was up. Something to consider, I can't remember which member told me to try it or I would credit them :{  

Husker7.3

Since this post thread got started back up I will throw another possibility. Previous owner had a aftermarket stereo in mine and I was messing with the battery. I then had the same problem with no response from PCM. It was because I disconnected the ground from my PCM that was to my drivers side battery.  

Bigjlambert

Im having this problem with a 2002 I just bought at an insurance auction, it was hit at LF fender. Not able to connect to a code reader, no power at the IPR, fuel pump, or inertia switch. Anybody come up with a solution to their problem???  

Sbluke55

There is a circuit breaker under the air box labeled high voltage. You can just cut it out and connect the wires back together.  

I robbed a PCM out of a 2000 7.3 and tried it and then had power at the IPR and fuel pump and was able to connect a reader and pull codes. After a while of cranking she fired up. Woohooo. Gauges and things arent woking but im sure thats because its the wrong PCM for my truck from an earlier non digital tach system. Now i guess I will send my PCM off to have repaired since a reman one is $750. The repair was quoted from SIA electronics at $189.99. With lifetime warranty and plug and play ready. Anybody heard of them or have experience with them?  

Well I sent my pcm off to get fixed. Got it back and plugged it in and it fired up and everything worked, no codes, no dash lights. It sat for a week and now it's DEAD again. No communication with a code reader no blown fuses. :crying:  

You could search the junk yards and get one for under $50. I've never heard of those people you posted.  

Update, we have found that if the batteries and the pcm are unplugged for a while then put back in it will start again and run for a few cycles then die again and is unable to connect to a reader. What the heck? Any ideas from you big brain PS owners?  

Has anyone figured this out yet? I have the same problem but I believe that my pcm is bad. I've been having problems with the truck dying intermittently. I have a 6 position chip pluged in and when I touch it the truck dies. I was working under the dash today with the key on and noticed the chip not in correctly. Hasn't started since and no comms with AE. All fuses are good, no fuel pump but all of the dash lights work. Anyone have a good place to send it to get it fixed?  

Bugman

Pull the chip and see if it cures the problem. When you say that if you touch the chip the truck dies is pointing towards the chip not being properly seated and if it does come loose enough it will fry the PCM if the power is on.  

Sounds like I fryed the pcm as when this all happened the chip was not seated properly with the power on. In the past week or so with my dying problems I could pull the chip and the truck would start. Now I have no start and no fuel pump.  

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A posteriori accuracy estimations of solutions to ill-posed inverse problems and extra-optimal regularizing algorithms for their solution

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  • Volume 5 , pages 68–83, ( 2012 )

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A new scheme of a posteriori accuracy estimation for approximate solutions to ill-posed inverse problems is presented along with an algorithm of calculating this estimation. A new notion of extra-optimal regularizing algorithmis introduced as a method for solving ill-posed inverse problems having optimal in order a posteriori accuracy estimation. Sufficient conditions of extra-optimality are formulated and an example of extra-optimal regularizing algorithm is given. The developed theory is illustrated by numerical experiments.

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2002 ford excursion 7.3 diesel problems

Regularizing algorithms with optimal and extra-optimal quality

A. S. Leonov

Extra-Optimal Methods for Solving Ill-Posed Problems: Survey of Theory and Examples

Locally extra-optimal regularizing algorithms and a posteriori estimates of the accuracy for ill-posed problems with discontinuous solutions.

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Original Russian Text © A.S. Leonov, 2012, published in Sibirskii Zhurnal Vychislitel’noi Matematiki, 2012, Vol. 15, No. 1, pp. 85–102.

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Leonov, A.S. A posteriori accuracy estimations of solutions to ill-posed inverse problems and extra-optimal regularizing algorithms for their solution. Numer. Analys. Appl. 5 , 68–83 (2012). https://doi.org/10.1134/S1995423912010077

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2002 ford excursion limited diesel for sale by owner - Ocala, FL -...

Selling 2002 4x4 7.3 Limited Excursion Truck runs and drives great ac is Ice cold my grandfather bought it from a diesel mechanic that maintained it meticulously and did tons of upgrades to it body...

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3-day Moscow excursion package

2002 ford excursion 7.3 diesel problems

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► Tours    ► St Petersburg and Moscow tours   ► 3-day Moscow excursion package

2002 ford excursion 7.3 diesel problems

Three days in Moscow is enough to see and enjoy the best sights the Russian capital has to offer. Moscow is over 850 years old and in all these centuries it has acquired a great deal of cultural and historical heritage, which offer stands side by side to features of a modern metropolis. On this three-day tour in Moscow you will of course see the Kremlin – the historical kernel of the city which is now the official residence of the Russian president. You will also visit one of the country's most recognisable symbols – St Basil's Cathedral, plus the beautiful Novdevichy Convent and the Tretyakov Gallery - a treasure trove of Russian art. You will also see some of the monuments of the Soviet era such as the Moscow Metro and the VDNKh Exhibition Centre, where leading artists, sculptors and architects have managed to embody the political ideology of the time in the complex’s style.

All excursions are run by experienced, licensed guides who will show you Moscow’s most beautiful places and tell you about their wonderful history and legends about them.

  DAY1 | MUST-SEE MOSCOW SIGHTS

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  • Red Square – Moscow's and Russia’s main square, where the Victory Day Parade is held annually in May.
  • St Basil’s Cathedral (including interior) – undoubtedly one of the most recognisable cathedrals in the world. Its fairy-cake like domes are unmistakeable.
  • Lenin’s Mausoleum – here the founder of the Soviet Union still lies embalmed 90 years after his death. He was briefly joined by Stalin, but Stalin's body was buried behind the mausoleum during the de-Stalinisation period.
  • Aleksandrovsky Gardens – these beautiful gardens run along the northern wall of the Kremlin, where once the River Neglinnaya flowed before being diverted underground – previously the kremlin was surrounded on all sides by water. There are many interesting memorials here to historical figures.
  • Zaryadye Park - thanks to the creation of this wonderful new park in the very centre of Moscow, the beautiful churches of Ulitsa Varvarka are no longer hidden away and new views of the kremlin and river have been opened up.
  • Christ the Saviour Cathedral (including interior) – this is Russia’s main cathedral and one of its largest. It was rebuilt after the fall of the Soviet Union on the site of the original, which was destroyed on the orders of Stalin to make way for a giant Palace of the Soviets. However the palace was never built and instead there was an open-air swimming pool here during the Soviet period.
  • Bolshoi Theatre - this is one the most famous ballet theatres for in the world. It is a symbol of Russian culture and national pride. Its name though rather unglamorously translates as Big Theatre.
  • GUM Department Store – this grand shopping centre is another famous symbol of the city.
  • Ulitsa Vavarka – this is one of Moscow’s oldest surviving streets and it has the highest concentration of old and historic buildings in the whole city. You will find here St Babara’s Church (in honour of which the street is named), St George’s Church, the architectural ensemble of the former Znamensky Monastery, the English Court (an early English embassy) and the Romanov Court (the family estate of the Romanov family before becoming the ruling dynasty).

2002 ford excursion 7.3 diesel problems

  DAY2 | CULTURAL HERITAGE

2002 ford excursion 7.3 diesel problems

  DAY3 | SOVIET MOSCOW

2002 ford excursion 7.3 diesel problems

  • The tour is available the whole year round starting on any day, but please take into account that the museum’s working hours and days-off vary so we reserve the right to change the itinerary while trying to save the excursion programme.
  • Transportation can be changed to a car upon request, but please note that the transport situation in Moscow is not very good, so you could get stuck in a traffic jam.
  • Tickets to museums cannot be sold without an excursion with a guide.
  • During state holidays and celebrations, Red Square may be closed (either partially blocked off or completely closed).
  • All excursions/guided tours included in the itinerary are private which means private guides - unless otherwise stated.
  • Best time to travel on this route: from the end of April to mid-October and from December to mid-March.

•  CANCELLATION POLICY  •

2002 ford excursion 7.3 diesel problems

Date of the tour

Number of travellers.

2002 ford excursion 7.3 diesel problems

  • Private guide service according to the programme
  • Entrance tickets to museums.
  • Skip-the-line where available
  • Metro tickets

2002 ford excursion 7.3 diesel problems

  • Tips for a guide (optional)
  • Personal expenses

2002 ford excursion 7.3 diesel problems

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2000 Excursion 7.3 problem

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I just joined the site with the hope to try and figure out a possible problem before taking to Ford dealer for help. My 2000 Excursion with 7.3 has been very reliable and not given much of any problems. Engine has 160K miles. About a week ago, I was getting on the interstate and the vehicle began vibrating as I pushed the accelerator and acted as if the emergency brake was on. I pulled off the road and tried to look at and did not notice any visual problems and after 5 minutes looking, got back in the truck and it drove without any more incident. A day later the problem came back and now I have the vibration back and happens when I push the accelerator. Also, upon starting it up, it has some more white smoke than normal and the odor and much worse/stronger than ever before. I have tried to read posts and see potential issues, but wanted to throw out my situation and get any help. I appreciate any thoughts before I have to take to Ford dealer for diagnostic testing. If any has any good mechanics for powerstroke near Clarksville TN (45 minutes north of Nashville), let me know. Thanks for your help.  

Check your private messages....  

NoRalPh

Nope. Actually wound up being his fuel pump was bad. Caused by bad connections on the batteries.  

I know. I was kinda worried about that too, but it actually ran like a champ by the time the new pump was installed.  

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  20. 2000 Excursion 7.3 problem

    My 2000 Excursion with 7.3 has been very reliable and not given much of any problems. Engine has 160K miles. About a week ago, I was getting on the interstate and the vehicle began vibrating as I pushed the accelerator and acted as if the emergency brake was on. I pulled off the road and tried to look at and did not notice any visual problems ...

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