7.3 Power Stroke Maintenance Guide

Contents
  1. 7.3 Power Stroke Maintenance Schedule (Normal Conditions)
  2. 7.3 Power Stroke Maintenance Schedule (Severe Conditions)
  3. 7.3 Power Stroke Oil Viscosity Chart
  4. 7.3 Power Stroke Oil & Fluid Specifications
  5. 7.3 Power Stroke Oil & Fluid Capacities
  6. Relevant Service Part Numbers

Applicable Models:

1994.5 - 1997 Ford F-250, F-350, F-Super Duty
1999 - 2003 Ford F-250, F-350, F-450, F-550 Super Duty
2000 - 2003 Ford Excursion
2000 - 2003 Ford F-650, F-750
1995 - 1999 Ford Econoline E-350
2000 - 2003 Econoline E-350, E-450, E-550

Applicable Engine(s):

7.3L Power Stroke diesel V-8

Application Transmissions:

Ford E4OD four speed automatic
Ford 4R100 four speed automatic
ZF S5-42 five speed manual
ZF S5-47 five speed manual
ZF S6-650 six speed manual

Applicable Drivetrain:

2 wheel drive and 4 wheel drive models

7.3 Power Stroke Maintenance Schedule

The maintenance schedule for "normal" driving conditions assumes the vehicle is driven unladen in ideal traffic conditions with minimal engine idling and constant road speeds. A vehicle will fall under the "severe" or "heavy duty" service category if it meets any of the following criteria:

• Vehicle is idled frequently and/or excessively (generally defined as 10 minutes or more idling within a 1 hour window)
• Vehicle makes frequent short trips in which the engine often shutdown before reaching full operating temperature
• Vehicle is driven off-road or in conditions that require the 4 wheel drive to be engaged
• Vehicle experiences light towing/hauling in excess of 1,000 miles between oil change intervals
• Vehicle tows and/or hauls medium to heavy loads
• Engine is run on biodiesel or biodiesel blends (any concentration)

As a general rule-of-thumb, most owners of a heavy duty pickup truck or van will fall under the severe/heavy duty service category, requiring an alternative maintenance schedule calling for more frequent service procedures. If in doubt about which service category your vehicle falls under, always adhere to the more stringent severe/heavy duty service intervals.

Many service intervals are provided in distance driven OR a period of time; service should be performed when either of these two conditions are met, whichever comes first.

Normal Service Intervals

Service Procedure Service Interval(s)
Replace engine oil & oil filter Every 5,000 miles/6 months
Replace fuel filter Every 15,000 miles
Replace engine air filter Every 30,000 miles, 30 months, or as necessary
Serpentine belt Inspect at oil change intervals, replace as necessary
Flush/service engine cooling system 50,000 miles/48 months initially
Every 30,000 miles/36 months thereafter
Replace automatic transmission fluid & filter Every 30,000 miles
Replace manual transmission fluid Every 60,000 miles
Replace transfer case fluid Every 60,000 miles [1]
Replace front differential fluid (4x4) Every 100,000 miles [1]
Replace rear differential fluid Every 100,000 miles [1]

[1] - Replace fluid as soon as possible anytime the unit is submerged in water; water intrusion highly likely.

Severe/Heavy Duty Service Intervals

Service Procedure Service Interval(s)
Replace engine oil & oil filter Every 3,000 miles/3 months
Replace fuel filter Every 15,000 miles when using conventional diesel fuel
Every 7,500 miles when using biodiesel blends exceeding B5 (5% biodiesel)
Replace engine air filter Inspect at oil change intervals, replace as required
Replace regardless every 15,000 miles/12 months if driving in dusty conditions
Flush/service engine cooling systems 50,000 miles/48 months initially
Every 30,000 miles/36 months thereafter
Replace automatic transmission fluid & filter Ford E4OD (1994 - 1997) Every 21,000 miles
Ford 4R100 (1999 - 2003) Every 30,000 miles
Replace manual transmission fluid Every 60,000 miles
Replace transfer case fluid Every 60,000 miles [2]
Replace front differential fluid (4x4) Every 30,000 miles [2]
Replace rear differential fluid Every 30,000 miles [2]

[2] - Replace fluid as soon as possible anytime the unit is submerged in water; water intrusion highly likely.

7.3 Power Stroke Oils, Lubricants, & Fluids

Engine Oil Viscosity Chart

7.3L Power Stroke engine oil viscosity chart with ambient temperature ranges
7.3 Power Stroke engine oil viscosity chart

An engine oil viscosity grade should be selected based on the expected ambient temperature range in which the vehicle is to be operated. The 7.3L Power Stroke requires an engine oil that meets, at minimum, API CG-4/SH specifications. Note that certain viscosity grades are "acceptable" within a temperature range while others are "preferred". When possible, select an engine oil viscosity that is "preferred" within the expected temperature range. SAE 15W-40 is the most commonly used, readily available viscosity grade for the 7.3L Power Stroke.

We highly recommend a high quality synthetic motor oil due to its resilience against degradation and oxidation in engines employing an HEUI injection system. Synthetic motor oils will provide improved wear protection under the strenuous oil pressures these systems operate at.

Oil & Fluid Specifications

Fluid Type Oil/Fluid Specification Remarks
Engine oil SAE 15W-40 preferred in ambient temperatures > 30° F
Recommend Amsoil Max Duty Signature Series 15W-40 diesel oil
[3]
SAE 10W-30 preferred in ambient temperatures between -10 to 30° F
Recommend Amsoil Max Duty Signature Series 10W-30 diesel oil
SAE 5W-30 acceptable in ambient temperatures < 30° F
SAE 0W-30 acceptable in ambient temperatures < 0° F
Engine Oil API Category: CG-4/SH or equivalent ---
Engine coolant Motorcraft VC-5 green concentrated engine coolant mixed 50/50 with distilled water
Motorcraft VC-5-DIL green prediluted engine coolant (do NOT add water)
[4]
SCA/DCA Coolant Additive Motorcraft VC-8 cooling system additive ---
Automatic transmission fluid Ford E4OD Motorcraft MERCON V ATF (XT-5-QMC) [5]
Ford 4R100
Manual transmission fluid 5 speed (ZF S5-42, S5-47) Motorcraft MERCON V ATF (XT-5-QMC)
Recommend Amsoil Signature Series Synthetic ATF
---
6 speed (ZF S6-650)
Transfer case fluid Motorcraft MERCON LV ATF (XT-10-QLVC)
Recommend Amsoil FE Synthetic ATF as a high quality, full synthetic alternative
[6]
Front differential gear oil Dana 50 TTB (F-250 only) SAE 80W-90 gear oil (synthetic preferred)
Recommend Amsoil Severe Gear 80W-90 synthetic gear oil
---
Dana 60 SAE 80W-90 gear oil or SAE 90 hypoid gear oil (synthetic preferred)
Recommend Amsoil Severe Gear 80W-90 synthetic gear oil
Rear differential gear oil Sterling 10.25, 10.50 SAE 75W-140 full synthetic gear oil
Recommend Amsoil Severe Gear 75W-140 synthetic gear oil
[7]
Dana 80 SAE 75W-90 full synthetic gear oil
Recommend Amsoil Severe Gear 75W-90 synthetic gear oil
Dana 135 (F-550 only) SAE 80W-90 gear oil
Recommend Amsoil Severe Gear 80W-90 synthetic gear oil
Limited slip additive Motorcraft XL-3 friction modifier
Brake fluid Motorcraft PM-1 DOT 3 brake fluid
Recommend Amsoil DOT 3 synthetic brake fluid
---
Clutch hydraulic fluid
Power steering fluid Motorcraft MERCON V ATF (XT-5-QMC) ---

[3] - Refer to viscosity chart for complete viscosity grade application details; be mindful of the terms "preferred" and "acceptable". When possible, select a viscosity grade that is preferred within the expected ambient temperature range in which the vehicle is being operated.
[4] - 50/50 coolant-to-water ratio is ideal under most circumstances and provides protection against freezing down to -34° F. The ratio can be increased to 60% engine coolant, 40% water in extremely cold environments, as necessary. Do not exceed a 60/40 ratio.
[5] - MERCON V replaces original, now defunct MERCON specification in all transmission applications
[6] - MERCON LV replaces prior Motorcraft XL-12 transfer case fluid specification; MERCON V is not suitable for use in transfer cases
[7] - Limited slip differentials may require a friction modifier to prevent chatter; use Motorcraft XL-3

Oil & Fluid Capacities

Fluid Type Oil/Fluid Capacity Remarks
Engine oil 15 U.S. quarts [8]
Engine cooling system 1994 - 1997 7.2 gallons ---
1999 - 2003 8.2 gallons
Automatic transmission fluid E4OD, 4x2 15.7 U.S. quarts [9]
E4OD, 4x4 16.2 U.S. quarts
4R100 17.1 - 17.7 U.S. quarts
Manual transmission fluid 5 speed 3.4 U.S. quarts [10]
6 speed 5.8 U.S. quarts
Transfer case fluid 2.0 U.S. quarts [10]
Front differential gear oil Dana 50 TTB (F-250 only) 1.9 U.S. quarts [10]
Dana 60 2.9 U.S. quarts
Rear differential gear oil Sterling 10.25 (1994 - 1997) 3.75 U.S. quarts [10],[11]
Sterling 10.50 (1999 - 2003) 3.45 U.S. quarts
Dana 80 4.15 U.S. quarts
Dana 135 (F-550 only) 12.25 U.S. quarts
Brake fluid N/A; fill to reservoir marker ---
Clutch hydraulic fluid N/A; fill to reservoir marker/line ---
Power steering fluid N/A; fill to correct dipstick level ---

[8] - Refill capacity with filter change; some repair procedures may require additional oil to be added if the high pressure oil pump reservoir, hoses, or cylinder head oil rails are drained. Always verify correct engine oil level with vehicle parked on level ground.
[9] - Transmission fluid should be filled until the level has reached the appropriate dipstick indicator
[10] - Fill component until oil has reached the lower level of the fill plug hole; fill plug height is the appropriate lubricant level indicator. When checking fluid level, oil should be no less than 1/4 inch below the fill plug opening. Always fill and check fluid level with vehicle parked on level ground.
[11] - If friction modifier/additive is required for limited slip differential, add before filling with gear oil

7.3 Power Stroke Service Parts List

Part Description Part Number(s)
Engine air filter 1994.5 - 1997 Motorcraft FA-1617 (Ford F5TZ-9601-A)
1999 - 2001 Motorcraft FA-1680 (Ford XC3Z-9601-AA)
2002 - 2003 Motorcraft FA-1750 (Ford 2U2Z-9601-AA)
Engine oil filter Motorcraft FL-1995
Engine oil fill cap Motorcraft EC-743 (Ford F3AZ-6766-B)
Oil pan drain plug Ford F6TZ-6730-AA
Fuel filter 1994.5 - 1997 Motorcraft FD-4595 (Ford F4TZ-9N184-A)
1999 - 2003 Motorcraft FD-4596 (Ford F81Z-9N184-AA)
Fuel filter housing cap/lid 1994.5 - 1997 Ford 5TZ-9G270-A
1999 - 2003 Ford F81Z-9G270-BA
Lift pump (fuel pump) 1994.5 - early 1999 Ford F6TZ-9350-A (mechanical engine mounted lift pump)
Late 1999 - 2003 Bosch 69136, Ford F814-9350-AA (electric chassis mounted lift pump)
Serpentine belt 1994.5 - 1997 Motorcraft JK81195 (single alternator configuration)
1999 - 2003 Motorcraft JK81227 (single alternator configuration)
Glow plug Motorcraft ZD-11 (Ford F4TZ-12A342-BA)
Glow plug relay Ford F81Z-12B533-AC
Thermostat 1994 - 1995 Ford F4TZ-8575-CB
1996 -2003 Ford F6TZ-8575-EA
Thermostat housing gasket 1994 - 1995 Ford F4TZ-8255-A, Victor Reinz C32036
1996 -2003 Motorcraft RG602 (Ford F81Z-8255-AA)
Radiator overflow/degas cap Ford 9C3Z-8101-B
Upper radiator hose 1994.5 - 1997 Motorcraft KM2989
1999 - 2003 (single alt) Motorcraft KM4495
1999 - 2003 (dual alt) Motorcraft KM4351
Lower radiator hose 1994 Gates 21405
1995 - 1997 Gates 22216
1999 - 2000 Motorcraft KM4542
2001 (built before 4/29/01) Motorcraft KM4542
2001 (built after 4/29/01) Motorcraft KM4671
2002 - 2003 Motorcraft KM4671
Block heater coil Ford F7TZ-6A051-AA
Cam position sensor (CPS) Ford F4TZ-12K073-C
Exhaust backpressure sensor (EBP) Motorcraft DPFE3 (Ford 4C3Z-9J460-A)
Exhaust backpressure sensor tube 1994.5 - 1997 Ford F4TZ-9D477-A
1997.5 - 1998 Ford F7TZ-9D477-AA
1999 - 2003 Ford 1C3Z-9D477-AA
Turbocharger up-pipe gasket 1994.5 - 1997 Mahle/Fel-Pro 8194
1999 - 2003 Ford F4TZ-6K854-C
Injector control pressure sensor (ICP) 1994.5 - 1996 Ford F4TZ-9F838-A
1997 - 2003 Ford F6TZ-9F838-A
Injection pressure regulator (IPR) 1994.5 - 1995 Ford 2C3Z-9C968-BA (serial # 501 - 187,099)
1996 - 2003 Ford F81Z-9C968-AB (serial # 187,100+)
Engine oil cooler Ford 1C3Z-6A642-AA (cooler only, does not include front or rear header)
Automatic transmission filter Ford YC3Z-7A098-BA (E4OD & 4R100 transmissions)