7.3 Power Stroke Turbocharger Removal & Reinstallation

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 V-8 (7.3 DIT)

Pulling the turbocharger on a 1994 - 1997 "OBS" and early 1999 Super Duty is quite a headache the first time around - don't be discouraged, you'll be an expert by the time you're done. And if you happen to forget the tricks and tips you taught yourself the first time, the procedures below will walk you through it. The problem with removing the turbo on these model year pickups is not only that access is relatively difficult, but we're talking about trucks that are 20+ years old and thus many of the bolts/nuts are likely frozen. Exhaust hardware is stubborn in general, and it doesn't help that the up-pipe to turbine flange is difficult to reach with normal hand tools.

Removing and installing a turbocharger on a late 1999 - 2003 Super Duty equipped with a 7.3L Power Stroke is relatively straight forward. In fact, it's easy in comparison to removing the turbo from an earlier 7.3L Power Stroke or the later 6.0L Power Stroke. With the turbocharger removed, inspect the up-pipe collector gaskets; they should be replaced if the collector moves excessively or there are signs that the collector donut gaskets are leaking.

Parts List for Turbocharger Installation

Part Description

Part Numbers


GTP38 turbocharger reinstall kit

Ford F81Z-6N653-BA
International 1831658C91


Up-pipe collector to turbine inlet clamp

Ford F81Z-8287-EA


Turbine outlet to downpipe clamp

Ford XC3Z-5A231-AA


Compressor outlet to intake "spider" plenum clamp

Ford 1831214C1


[1] - Can be reused if condition is acceptable; replacement is highly recommended

Late 1999 to 2003 Turbo Removal Procedures

Click any thumbnail to view high resolution fullsize image w/ addition details (where applicable)

Intercooler tube disconnected

• Disconnect both negative battery cables.

• Loosen clamps and disconnect intercooler tubes from the intake "spider" plenum. You do not need to remove the intercooler tubes completely, although it does leave more room to work if they are removed.

Plenum closeup

• Remove air intake heater (AIH) wire leads (pair of lug connectors).

• Disconnect intake air temperature (IAT) sensor connector.

• Disconnect manifold absolute pressure (MAP) sensor supply line.

• Disconnect wastegate pressure lines from wastegate solenoid and intake plenum.

• Remove wastegate solenoid from intake plenum (8 mm socket).

Wastegate actuator closeup

• Disconnect wastegate pressure line from wastegate actuator mounted near the rear of the turbocharger on the compressor side.

• Remove intake tubing between air filter box and turbocharger inlet.

All sensors and lines removed from plenum

• The intake plenum should have no wires, hoses, or connections attached to it at this point.

• Loosen the intake boots at the outlets of the intake plenum that feed into the intake manifolds at each bank of the engine.

Plenum to turbocharger clamp

• Generously loosen the Marman clamp connecting the intake plenum to the turbocharger compressor outlet.

• Loosen the clamps attaching the intake manifold boots to the intake plenum on each bank.

Removing intake plenum

• Pull the intake plenum outwards to break the seal between it and the turbocharger, then pull the plenum upwards to remove from the engine. There is an o-ring seal between the plenum and turbocharger - discard it, this does not get reused.

• Cover the now exposed intake manifold openings on each bank with clean rags to keep debris out.

Removing exhaust downpipe

• Generously loosen the Marman clamp attaching the exhaust downpipe to the turbocharger turbine outlet. Disconnect the downpipe from the turbocharger and allow it to hang freely.

If replacing up-pipe gaskets, separate the downpipe from the exhaust system, then completely remove it from the vehicle. Separating the downpipe from the exhaust system may prove difficult - penetrating oil, patience, and a dead blow hammer will make matters easier.

Disconnecting EBPV linkage from turbo

• Disconnect the exhaust backpressure valve (EBPV) linkage from the turbocharger. To do so, locate the small sliding clip on the bottom of the link. Slide the clip towards the driver's side to disconnect. The linkage does not get completely removed at this point.

Removing exhaust up pipe collector clamp

• Locate and remove the Marman clamp connecting the exhaust "Y" collector to the turbocharger turbine inlet. Once the clamp is loosened, you will need to pry the clamp off with a screwdriver - these have a tendency to stick.

Turbocharger to pedestal mounting bolts

• Remove the two turbocharger mounting bolts located between the compressor and turbine housings.

Removing turbocharger

• Position the turbocharger forward until it releases from the exhaust "Y" collector, then guide the EBPV linkage off of the backpressure valve swing arm as you lift the turbocharger upwards slightly.

• Carefully remove the turbocharger from the vehicle. The turbocharger is heavy and can be awkward to guide out of the engine - be patient and maneuver cautiously.

Turbocharger Reinstallation

Replacing turbo pedestal o-rings

• Replace the pair of turbocharger pedestal o-rings - these are not to be reused. Lightly lubricate them with clean engine oil prior to installation.

• Install a new Marman clamp on the exhaust "Y" collector loosely as not to interfere with turbocharger re-installation.

• It is recommended to replace the EBPV linkage clip with a new one, as supplied in the turbocharger reinstall kit, before reinstalling the turbo.

• Reinstall the turbocharger onto the turbo pedestal then line up and reinstall the EBPV linkage. Also ensure that the indentation on the turbocharger turbine is properly aligned with the "Y" collector alignment pin, then install the turbocharger to pedestal bolts hand tight. Ensure that the pedestal o-rings have not been dislodged by mistake

• Torque turbocharger pedestal bolts to 18 ft-lbs.

Reinstalling turbocharger

• Align, tighten, then torque the exhaust collector to turbine Marman clamp to 60 in-lbs.

• Reinstall the exhaust downpipe, torque Marman clamp at turbine outlet to to 60 in-lbs.

• Remove any rags in the intake manifold openings, then reinstall the intake manifold plenum using a new o-ring seal between the plenum and turbocharger compressor outlet. Lightly lube the new o-ring with clean engine oil.

• Tighten intake plenum to turbocharger clamp - snug, do not over-tighten.

• Tighten intake manifold to intake plenum boots.

• Reinstall intercooler tubes to the intake plenum, tighten all clamps.

• Reinstall remaining sensors, intake tubing, and wastegate actuator lines.

• Reconnect negative battery cables, start engine, and test for leaks and/or additional problems.