I bought a 1995 F350 dump truck with the 7.3L Powerstroke back in May of 2012. The truck was pretty solid expect for the fact that the brakes were gone and the truck smoked at startup. Having a 1995 F250 with a solid running 7.3L, I figured I would be able to diagnose the problem and get it to stop smoking.
I replaced the injector O rings and check the resistance in the glow plugs to start. The old injector O rings were pretty decent, but they are under high pressure so it would be hard to tell by eye. By replacing them I felt I could eliminate them as a cause of the smoke. I replaced them, and it still smoked, but not as bad. During ‘field testing’ the truck died. I had to replace the injector pressure regulator (IPR
) sensor. I replaced it and the truck started right up.
During a second round of ‘field testing’ the truck died again. This time it was a fuel issue. I replaced the fuel pump, in a parking lot, and the truck eventually started up after it was primed with fuel. The truck ran good, and passed inspection and diesel emissions. There was a noticeable difference between the F350 and my F250. My F250 feels like a rocket ship, where the F250 always dogged around and felt like it was going to die. I began to think it was related to injectors.
I decided to do some trouble shooting. I looked in and around the turbo for excess oil, and I did not see anything to make me think there was a major leak or anything. I did notice that the fins on the turbo were slightly bent, but the bearing was good and the turbo fan spun freely. I will mention now that the truck’s air box was completely smashed and held together with duct tape. (Not my doing…) I found a stock air box and the junk yard and swapped it into the truck.
After some thought, I decided to do a compression test. The compression overall was low. I also found some small debris in the top of the head. In my opinion, when the air box got smashed, it sucked small parts of plastic into the motor and caused some damage. I have not taken the heads off to take a look, but maybe after I pull the motor I will. After thinking about this for a little while, I decided to look for a replacement motor. I found a nice motor from a reputable guy that I have done business with and started to plan the swap.
After acquiring the motor, I decided to reseal as much stuff as possible while the motor is out and do as much preventative maintenance as I could. I also decided to install a new downpipe to replace the factory ‘pancake’ pipe. I’ll post some pictures of the swap as I move forward.