Ford 7.3L Power Stroke (1999-2003) :: Engine Has A Cracked Piston
Jan 7, 2016
I need a film crew to document this stuff, but here's what I've got. This engine had a cracked piston. It is currently torn down and ready to go to the machine shop. I ordered a powder coating set up, so everything that fits in the oven will get powder!
This engine will get cut/coated pistons, cryoed forged rods, 250/100's, waste gated T4/S369, head studs, 910 valve springs, smith bros pushrods, etc. We'll also be using a Southbend dual disc clutch in front of the freshly rebuilt ZF6.
Here's some of the shiny stuff.
I think I'll give up a little top end to spool faster. Especially since this is a 6spd build.
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Chasing this knock and I'm starting to get a little bit worried. So I'm looking for what I should do next.
Here is the truck info... 2000 F250 4x4 206k. . Swamps Diesel 200/30's. Terminator HPOP. GTP38R. EBPV delete pedestal. Banks wastegate. AFE stage 2 intake. RiffRaff FRX. 4" exhaust. Hydra chip. John Wood Auto. 6.0 Trans cooler.
I have a knock sound coming from the area of #8. It is noticeably louder in that area with a stethoscope. Its not any louder anywhere else (oil pan, block, otherside of engine, or front). Truck does not smoke and runs and idles great otherwise. Was thinking possibly the cackle/fuel knock issue these trucks have but with bigger injectors and the FRX could this even still be a possibility?! Anyways here is what I've done.
Checked fuel pressure and at idle it is 61/62 with any tune. At WOT on Econ tune it goes down to ~40ish psi. With the extreme tune WOT dived down to 28/29psi. So my thinking was maybe that injector got screwed up so...
Swapped #8 injector with #2 so the front injector with the back to see if either it had some bad o rings or isolate the injector as the problem if the noise moved cylinders with the injector. While I did this I put brand new O-Rings on those two injectors and popped them in. Got it fired up and the knock is still in #8.
Unplugging the injector with the engine running the noise seems to disappear. HOWEVER, when I use the stethoscope the knocking noise still sounds like it's there but very faint. Without the stethoscope I can't hear it. Also driving the truck down the freeway and letting it coast the noise goes away when the injectors get cut off.
Recently pulled off valve cover and checked the pushrods and rockers on #8 and all looked fine. At this point I'm thinking wrist pin, rod bearing or cracked piston??? Could it somehow still be a fuel knock?
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I have a late 99 7.3 that developed a knocking noise. I pulled the passenger's head and cylinder 5&7 have a spot where it looks like it came in contact with the valve. I'm not some master mechanic but am learning. What would be my next step to find why it hit the valve and to fix the problem?
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Well my hpop is cracked and leaking alot I need to get home this sucks I must of tighted it too hard
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I had a brake line crack on my way home yesterday(that was interesting..) It was the drivers side rear metal line from the splitter to the rubber hose. I went to autozone and was like ok easy enough this line is the same length and appeared to be the same diameter. bend to fit and all was well or not.. the fitting on the end was a different thread pitch and size. 1999 f250 4wd if it matters....
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So I recently attempted to change the brakes on my 96 dodge dakota. I followed the instructions in my Chilton manual to do it. The driver side was no real problem and managed to get it done within an hour. Now knowing how to do it I moved to the passenger side. Once I slid the caliper off the rotor I noticed that the pads on this side were nothing but metal but the rotor was fine. I took out the pads but the piston was hyperextended and there was no way to compress it no matter what I did. The piston eventually just started to crack away. So I went to O'Reilly's and bought a refurbished caliper. It looked very similar and fit the bolts. However when I tried to attach the brake line it was at a different angle then its fitting. The brake line is a thin metal tube for the last 6 inches with a square piece of metal at the end where the hollow bolt goes through and then into the caliper. But because of the metal section I cant angle the brake line correctly to get a good seal.
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Last November I forgot to plug my truck in and it got down to 0, my girlfriend tried unsuccessfully to jump start it. When I got home I jumped it and got it running. I took it down to a heated shop to troubleshoot the glow plug circuit. I discovered it was not getting 12v to the glow plug relay. Also I started it and tried to back it up in the shop, when put in reverse it killed the engine, not lugged it down it was like you shut the switch off.
Also I discovered if you turn the lights on it kills the engine immediately. It will not crank with the lights on either. So far I have replaced the computer,ignition switch,batteries, and cam positioning sensor. Now comes the weird part!! I decided to get it running and pull the bulbs out of the back up lights I pulled the drivers bulb first then the passengers side bulb. When I pulled the passengers side bulb it killed the engine.
It is not my daily driver so it still sits in my shop. I have a hunch it's a ground issue but I've checked and cleaned up all the grounds I can find and it still has the problem.
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How my rings burnt up on one cylinder causing damage to my cylinder wall. My question is this. What could have caused this? I pulled the motor and tore it down. Cylinder wall is chewed up a bit so I was going to have the machine shop sleeve it. Is there another component that I should look at while it's apart? Also the corresponding freeze plug on the same cylinder was showing signs of leaking. I'm thinking that is related to the extreme heat that cylinder experienced.
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I have noticed a leak coming from the hydro boost piston that goes through the fire wall on the drivers side of my F250 King Ranch 6.0L... Here's the question, does the entire booster need to be replaced or is there an o-ring or a seal that can be replaced in the existing unit. I notice the fluid leaking on the piston just inside the firewall and it drips onto my floor mat.
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So on my way home today I lost all power, the engine shut of and i coasted to side of the road. Went to try and start, nothing. When key is in the crank position the gauges were jumping all over the place, also accompanied by a lot of clicking from behind the dash. Nothing happened when tried to crank. No power to windows or even emergency flashers.
So i get it towed home, and of course it turns over. But this only lasts about ten seconds, then dies. I could do that a few times and then back to no power at all. Even at times with the keys out of ignition it will still click and make a lot of noise.
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While pulling onto the highway and pulling pretty hard lost engine power all boost then engine truned off. Top of engine is covered in oil..... What happened?
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So after hitting a pothole, it would seem like half the engine lost power, after some searching around, i found that i would most likely be the harness inside the valve cover that has lost connection.
Its the right side, so i would need to take of the turbo pipe, and probably something else to get to it.
Since i'm doing this job, what to check out along the way? I want my 7.3 to be as reliable as possible.
I will probably ask some questions along the way, it can be a challenge sometimes to own a car that not many mechanics are familiar with, but as i have read online, this should be a very straight forward fix.
Can the harness be upgraded so it doesn't happen again? Its an 02
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Truck started losing power then service engine light came on, drove about another mile then it just stalled ( almost home lees than a 1/4 mile). Got out open hood oil everywhere on top of motor. Looked under truck and oil all over the road. Looked back where I was driving a line of oil as far an I could see. Checked oil barely any on stick. Where should I start hpop or plug?
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What I know the truck was running normal except if I stomped the gas pedal and let off it would not respond again until I shut off keys and restarted this was a month ago now the truck sounds like it has a lope tune.
When I hit the gas pedal it blows white smoke and if I press the gas while idling or driving it floods out I did the spray bottle test on manifolds the drivers side was plenty hot the passenger side is cold you literally can touch while it's running.
The truck sounds like it's only running on 4 cylinders it has gotten so bad I parked the truck. Also this truck always had poor mpg 8 to be exact city hwy and towing nothing changed the mpg at all it used to blow out wet soot that would fall down on the truck and anyone standing near it.
Mods unknown pcu program 4in straight pipe with 12in stack harpoon mod in tank
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Cooler weather has arrived and my 2000 f250 won't start. Wait to start light is coming on, no power passing through the two relays on top of the engine. Are both of these for glowplugs? My 97 only had one. How do I diagnose relays on this truck? If you cross out the two relays truck fires right off so I know the glowplugs themselves are good.
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Moving my worldly goods from California to Oklahoma in a rented 26' box truck with my wife following in our '02 F350 loaded to the gills with my lathe, mill, air compressor, weld and assorted machinery. Just west of Deming NM it started to blow lots of white smoke and down on power. Some rattling noises from the engine when throttled up & won't reach 3000RPM.
Had it towed to an impound yard for storage. Plan on sending a flat bed to pick it up when we get to Tulsa.
Any experience with a tilt back trailer capable of loading & transporting this truck that weighs around 17,000 pounds? My plan is to continue on to Tulsa & make arrangements from there.
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Had coolant in oil, so pulled motor. Got used motor to replace it with, thinking about doing some work on it before reinstall.
Got bellowed up pipes, injector o-rings, front and rear main seal, and will use best parts from both motors to make one. I'll also shim injector armatures back to spec.
Should I do injector cups too? What else is recommended to do at this time? Both motors are 350k or so, I was on a budget at a moment and have to make it work with what I got.
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My truck is for the most part fine, but it's doing some strange things and I'm wanting to get some opinions before I go and tow a trailer 300 miles next weekend.
Last weekend when I started my truck I had the CEL on for about a minute, then it went away. Not sure if it was an influencing factor, but it was sitting outside in the sun in 100 degree weather before I started it. Truck ran fine for the 300 mile trip home that day. Two days ago, I drove to my parents house. It ran fine the whole way there and as I pulled up into the driveway, the engine randomly got really choppy like it went down a couple cylinders or something. Not sure how to explain it. I pulled forward the last 50 feet or so I needed to drive with the engine chopping up, parked, unloaded the stuff I brought, and fired the truck back up to go home. It was running perfectly fine again and drove back home without an issue like nothing ever happened.
Is there any components I should be checking out on the truck before I make my next trip 4th of July weekend or just brush it off as being a fluke? Truck has 230k miles on it.
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I put a 150 w converter into one of my 12-watt power female and all of a sudden when i turned the engine on my check engine light came on with 4 glow plugs bad and now won't pass smog. any way i can turn off the check engine light so it won't comes up on the smog test?
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I bought a 2002 body with a late 99 engine with lower miles a couple years ago. I knew it had an oil leak when I bought it. My other truck had a turbo pedestal leak. This truck has a small pedestal leak but it's not that much of an issue as there is little oil in the valley and next to nothing running down the back of the engine.
The other leak is getting worse. It has been leaking somewhere up front and coats the main steering arm off the steering box, the lower rad hose and the rest of the steering linkage. Last night after driving around 100 Kms I have oil running out from under the engine across the floor.
I changed the LPOP after thinking the front leak was from there. Unfortunately i don't think it was.
I am hoping it's the oil cooler and not the HPOP. One other thing is before yesterday's trip, I installed my homemade ccv mod off my other truck. I don't think the leak is coming from that either.
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So I posted a while back about fixing all the leaks I had and what I was going to do. I finally completed all the repairs and reinstalled the engine and it won't start. Cranked a bunch and checked oil level in hpop its good so I pulled plugs in oil rails there is oil present there, cracked the yellow valve on fuel bowel there is fuel there. unplugged the icp sensor and cranked more still no indication of wanting to start.
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