Ford 7.3L Power Stroke (1999-2003) :: Tuck Has Developed A Knock Once Fully Warmed Up


May 8, 2016

Over the past few week my truck has developed a knock once it has fully warmed up. At first I thought it was possibly injector knock and kind of got excited about the prospect of upgrading to larger injectors. Well, my short lived optimism came to an end today once I got ahold of my father's mechanics stethoscope. So today I let it fully warm up and like clock work the knock came back. After going over nearly every inch of the top end, nothing was producing what I was hearing.

So I crawled under the beast and located the source. Right where the bellhousing mates the the engine block is where the knock is definitely loudest. At first I thought it was louder in while in gear but today it didn't matter if it was in gear or not. I removed the bellhousing cover and inspected what I could see of the flexplate. Couldn't see and cracks or breaks but from what I see through google searches is that it cracks behind the spacer. Now my first thought is that it's the flexplate but I'm hoping more experienced people can tell me what they think.

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Ford 7.3L Power Stroke (1999-2003) :: White Smoke At Startup And Knock When It Warms Up

So my truck a stock 2000 7.3 started smoking when I would start it up in the morning... figured it was a glow plug issue. Checked the relay it was good, checked the glow plugs found 2 were bad replaced them.

Thought I was done, well I started it up and took it for a drive. still smoked... thought no big deal I know some oil leaked into the cylinders doing the glow plugs.

Then it started rattling like a lift went out, no more smoke though because the truck was warm... shut it off at my buddies. Limped it "it actually still drives ok" 5 miles home.

From my research it sounds like an injector. I have tried a buzz test and they all sound the same.

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Ford 7.3L Power Stroke (1999-2003) :: 2001 F550 - Knock After Injectors Replaced

I just replaced all 8 injectors in my 01 F550 with remans from FFD. I have noticed a constant knock at idle but truck runs great. Blowby has no pressure behind it, truck does not smoke. Does this sound like a problem unrelated to an injector?

It did not make this noise before replacing the injectors

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Ford 7.3L Power Stroke (1999-2003) :: Intermittent Idle Knock Heavy Use Dependent

My late 99 has 161K, I am the 2nd owner and bought from the Original owner. It is stock with no tunes. Auto/4wd.

It has had an intermittent idle knock and recently has gotten much louder recently when used heavily with towing for summer camping in the 7K range up steep hills. The knocking goes away above 12-1500 rpm. There is no noise when the engine is cold. It seems heavily temp/load/heavy use dependent. If driven lightly, the knock is quieter but still present. The trans was recently rebuilt and new billet converter installed, made no difference so it's not that it would appear.

I rec'd blackstone last week and the results are excellent. Running the cyl contribution test while hot in drive at idle reveals cyl 8 is running 4.9 to 5.4 Perdels. #3 is 2.2 to 2.8. 1,6,7 are 0. 2 is .6 and 5 is .4.... I haven't checked bolt torque yet. My question: Is #8 "fixable" potentially with bolt torque? Is it considered too far gone and should just be replaced?

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Ford 7.3L Power Stroke (1999-2003) :: 2000 - Bad Miss Or Stutter / Knock At High RPM And Deceleration

2000 F250 7.3L ZF 6spd 4x4 regular cab long bed 253k

DP F6 chip, 4" exhaust, WW2, EBV delete

I run 5w40 Rotella Synthetic. Oil was changed about 1,000 miles ago. I also added a quart of Hot Shot stiction eliminator. I use Power Service and Stanadyne lubricity in every tank. Fuel filter is new.(motorcraft)

For a month or so its been acting weird. I get a stumble/miss/stutter, at random, but mostly under hard acceleration and high rpm (specifically approx 2500-2800rpm). It will also do it on decel when I lift after accellerating . Recently, I noticed it is also idling roughly. The engine is shaking and it feels like a miss. When it does its "thing" it sounds like a single "knock". Occassionally, it sort of sounds like an injector "buzzing". I've been using the "stock" tune for the last few weeks, to minimize any chance of engine damage, as I have to drive it. Turning up the chip makes the problems more noticeable and happen at a lower rpm. The truck has plenty of power, and pulls hard, except for the "stutter". If I hold my foot in it to "push through" the initial stumble at 2500 or so, it will keep going a few hundred more rpm, and then really start bucking.

There are no meaningful codes. I DO have:

EBV related soft codes - makes sense since its deleted.
Overboost related codes- from turning the chip up - won't happen in stock setting
A soft code for the back pressure SENSOR. I have a new one and will be cleaning the tube when I get a chance. I unplugged the sensor and it made no difference in the miss issue.

I have recently done the following in pursuit of a solution to all this:
New IPR (autozone) valve and pigtail
New ICP (motorcraft) and pigtail ( sensor had oil in it)
New CMP and pigtail. (2 actually. First a standard pc139 for the obs, and currently a Napa echlin correct for '00) No change. Although it initially had the dreaded Ford small head light grey sensor and failed cct for #3 & 8. After the cps change, it passed cct.

Accellerator Pedal Position Sensor. It would not read any higher then 3.95v at wot, and only 0.50v at idle, so I installed a new one. After adjusting it a little, I have 0.76v at idle, and 4.02 at wot. Didn't affect the stumble issue, but it seemed to greatly improve/eliminate my parking lot speed "bucking".

I just did the UVCH's. The passenger side was pretty much unplugged. But they all looked good. No burnt, melted,or chafed wires anywhere. I probably could have just plugged it back in, but I changed both sides with new Motorcraft parts anyway. I did the gaskets and the uvch, but not the engine side harness/pigtail, as they looked ok. I also did the 0.50 mod as a preventative measure. After seeing the unplugged harness, I really thought this would be the end of the problem, but its not. Very frustrated.
As a side note, I was surprised to see that I have 8 AD injectors, and not an AE in cyl 8.

I have an old outdated snapon scanner. Its only good up to '99, but I am able to scan my 2000 as a '99. I think I'm missing some pids though.
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As far as ICP, it idles at about 450psi, at approx 12% IPR dc. On a brief 2nd gear wot run, it will hit (and hold as long as I have road to stay in it) a little over 2900psi, at 41-42% IPR duty cycle. I did notice, during these near instantaneous stumble events, ICP would flutter on the scanner about 75-100psi. Its almost too quick to even see it.

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I added some good diesel additive to the fuel, hoping that may work, but it did not. I've been doing some reading in different places and am thinking of disconnecting the ICP sensor and see if it works. I also am considering trying some RevX, or similar stiction additive, but from what I've read, stiction is a cold start and chugging problem, of which I have neither. I have a ScanGuageII with many of the X gauges programmed in, but I am not quite sure what direction I should go.

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The last vehichle that i heard this from was my dd and ended up being a pinion bearing.

I put it on jack stands, removed the tires axles and driveshaft, spun the pinion yoke by hand it feels smooth. I also checked the rear hub bearings and they feel fine also. With the axles out and it up on jack stands i ran the truck and could still hear the noise. It almost sounds like it is comeing out of the T case output. The T case is a NP 271(manual shift).

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Here is a video around the exhaust area.

Here is up underneath the truck.

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