7.3L Ford Engine Rebuild Project: Domestic Diesel

Some time back, John Ferguson, the owner of Domestic Diesel in Chino, California, was approached by a long-time customer looking to unload a well-used 7.3L-powered Ford pickup from his work fleet. The clock showed a hard-earned half a million miles, hardly ideal under typical circumstances but it was the service performed by Domestic Diesel over the years that had helped get it there. The service history and the relatively low asking price presented Ferguson with an offer too good to turn down and in no time Domestic had a new but seriously worn-out shop truck. The most obvious issue was undoubtedly going to be the high-mileage motor and trans but at least it was a case of better the devil you know than the devil you don’t. Its potential was abundant and thus, a project was born.

When we heard about this 7.3L Ford engine rebuild project, we jumped at the chance to provide a detailed look at what it takes to do a better-than-new rebuild on a diesel engine. After all, how often does anyone get the chance to see the bare bones of these motors, motors that, more often than not, last longer than most cars?

1. Our 7.3L Ford (International) V-8 diesel was sent to L&R Machine where it was completely stripped and cleaned. Here you see the block coming out of the hot tank.

2. Once clean it’s thoroughly checked for any cracks. L&R uses a very strong magnet and some iron powder for this, as cracks will show as an irregular pattern in the powder. Thankfully our engine block was crack free.

3. The block is put on a boring machine to ensure that all the piston holes (bores) are round, straight and of the same size. We tried for a .020 over, but .030 was required to ensure full cleanup. — 3. The block is put on a boring machine to ensure that all the piston holes (bores) are round, straight, and of the same size. We tried for a .020 over, but .030 was required to ensure full cleanup.

John’s crew began, of course, by removing the engine from the truck before stripping it down to the heads to ship off for a rebuild. For those in the know, this is called a long-block, as heads are included in the package. The well-worn powerplant was then sent off to L&R Automotive in Santa Fe Springs, California, for a complete rebuild.

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On receiving the 7.3L Ford (International) V-8 diesel, L&R stripped it down and cleaned everything in preparation for machining. The cleaning process, usually called “hot tanking,” is essentially where the parts are removed and then put into what looks like a dishwasher on steroids. The engine parts come out clean, steaming and grease free. From there, the parts are sent to respective workstations for the rebuild process; heads go one direction, and the block and related parts go another.

On the block side, the first thing that is done is a thorough check for cracks, a process called Magnaflux. L&R uses the old school method of using a very strong horseshoe magnet and iron powder. The magnetic lines are interrupted by a crack and this shows in the pattern the iron powder displays. There are more modern, electromagnetic kits available that essentially do the same thing. Once a block is determined to be crack free, it moves on to the machining center where it’s checked to determine the bore diameter and the taper of the cylinder. If it’s within machinable specs, the cylinders are bored out to accept slightly larger pistons. Typically engines are bored .030 over stock, and .060 is usually the maximum.

4. After boring the block’s cylinders, it’s then sent to the honing machine. Honing the cylinders makes them all the same size and provides a better surface finish. This ensures a good seat of the piston rings and a long engine life.

5. This Sunen bore diameter indicator is used to check the cylinder bore diameter and taper. It reads in at .0005, half a thousandth less than the diameter of a human hair. — 5. This Sunnen bore diameter indicator is used to check the cylinder bore diameter and taper. It reads in at .0005, half a thousandth less than the diameter of a human hair.

6. The crankshaft of the engine is the main rotating part. It rides on bearings that are supposed to take the stress and wear as the engine run. Unless you have an engine with a spun main bearing, a simple, light-touch line hone operation for the mains should be all your engine needs. If not, a line boring will clean up the crank journals. Here you see a line hone operation being performed by L&R on our 7.3L block. — 6. The crankshaft of the engine is the main rotating part. It rides on bearings that are supposed to take the stress and wear as the engine run. Unless you have an engine with a spun main bearing, a simple, light-touch line hone operation for the mains should be all your engine needs. If not, a line boring will clean up the crank journals. Here you see a line hone operation being performed by L&R on our 7.3L Ford block.

7. L&R also services the heads for the 7.3L refresh. First, the heads are stripped and cleaned. Then they are surfaced, as you see being done here. Surfacing the heads ensures a flat surface and a good seal of the head gasket. — 7. L&R also services the heads for the 7.3L Ford refresh. First, the heads are stripped and cleaned. Then they are surfaced, as you see being done here. Surfacing the heads ensures a flat surface and a good seal of the head gasket.

8. After a head is cleaned and surfaced, the valve seats are cleaned and resurfaced. The valve guides are also checked and renewed to spec if required. The final step is to install either new or reground valves in the valve pockets.

9. Once the valves are in place, the valve springs and retainers are installed and the heads are then ready to be bolted to the block. Refurbishing heads on lower mile motors is sometimes done, while leaving the bottom end of the motor alone.

Boring a cylinder leaves a rougher than ideal surface and so they are typically honed to final size. This gives a better surface finish for the piston rings to seat against as it’s critical the ring seal must hold back the high compression of a diesel engine and not allow it to blow past.

In addition to the cylinder bores, the block deck, or top that the heads bolt to must be completely flat. This surface is often refinished along with the actual cylinder heads to ensure proper seating. Essentially, every critical surface interface in your engine is checked and refinished as required for optimal precision. L&R is able to take this process to the highest level, as they are a small, detail-oriented shop and not a mass-production facility.

10. Here you see the two types of OEM piston rods used in the 7.3L diesel engines. On the left is one of the later model forged rods with cap studs. On the right is a powdered metal rod that uses rod bolts. The forged rods are preferable. The bolt-style rods have been tagged as “crack rods” by Ford diesel enthusiasts, as they tend to crack on the bolt interface, when the stock bolts stretch. APR offers a rod bolt kit for this type of rod, which greatly lessens this problem. The forged rods are still preferred, but your motor might not come with them. — 10. Here you see the two types of OEM piston rods used in the 7.3L Ford diesel engines. On the left is one of the later model forged rods with cap studs. On the right is a powdered metal rod that uses rod bolts. The forged rods are preferable. The bolt-style rods have been tagged as “crack rods” by Ford diesel enthusiasts, as they tend to crack on the bolt interface, when the stock bolts stretch. ARP offers a rod bolt kit for this type of rod, which greatly lessens this problem. The forged rods are still preferred, but your motor might not come with them.

11. Derek Ranney, manager and co-owner of L&R Automotive, inspects the new MAHLE pistons before they’re installed in our 7.3L diesel. L&R has been in business for 38 years and supplies engine parts as well as top quality machine work for all types of engines. — 11. Derek Ranney, manager and co-owner of L&R Automotive, inspects the new MAHLE pistons before they’re installed in our 7.3L Ford diesel. L&R has been in business for 38 years and supplies engine parts as well as top quality machine work for all types of engines.

12. After the refurbishing, the block is ready for reassembly. Here you see the camshaft being installed. Since this engine is for a shop truck, a stock profile camshaft was used. For more performance, you can look to the aftermarket for many different grind profiles.

13. Here you can see the piston oilers. These must be installed, and this is best done before the camshaft. Do not forget them if you’re doing the assembly work yourself.

With all the machining completed, engine reassembly can begin. While most folks don’t have the necessary skills or specialized equipment to perform the machine work, it’s not uncommon to see owners and shops do engine assembly themselves. In this case, Domestic Diesel opted to have L&R build the short-block and return it to them with the refurbished heads for final engine assembly.

A few upgrades were made, such as adding ARP main studs and an upgrade to the better quality 7.3L Ford factory forged rods. MAHLE pistons and rings were also installed by L&R.

Next time, we’ll show you the final engine assembly back at Domestic Diesel and cover a few must-have upgrades as they reenergize the truck and roll it in to a brand new career. DW

14. The piston rings are installed and then the ring gap is checked. The rods can then be installed on the pistons. Our 7.3L diesel uses snap rings to retain the pins and the pins easily slip into place. Other engine applications require a press fit of the piston pins.

15. Here you see the crank bearings being installed in the block. These bearings and the crank journals must have a tight fit to maintain engine oil pressure. L&R ensures your motor goes together with the proper bearing clearance for the application and intended use. Be sure to use assembly lube if you’re installing the crank yourself.

16. Installing the crank is best done with two people. The crank is heavy and literally dropping it in, or just dropping it, can cause parts damage and personal injury.

17. A great upgrade for any engine is a set of main studs. Our 7.3L was upgraded with a set of studs from ARP. The studs are installed in the block, and then the main caps are dropped over them.

18. The ARP studs are treated with ARP’s “Fastener Assembly Lubricant” before being torqued down.

19. The main studs are torqued to spec, in the proper order and usually in several steps. ARP’s “Fastener Assembly Lubricant” reduces friction and helps ensure proper bolt torque values.

20. With the crank in place, the block can be flipped on its side and the piston and rod assemblies installed, one bank at a time. If doing the work yourself, take care to not scratch the crank journals with the rod cap studs during assembly.

21. With the piston and rod assemblies in place, the rod caps can be installed and torqued to spec. Again, this is done one bank at a time.

22. Here you see the pistons installed, note that the dome is not on center and that the pistons are marked as to which side faces the cam.

23. The cam and crank must be installed with the alignment marks on the gears matching, as seen here. Be sure this is done when doing the assembly yourself.

24. Here’s a comparison of the new ARP main studs, and the stock main cap bolts. Not only is the design of the stud setup stronger but the steel in the ARP studs is superior too.

25. Once your refurbished short-block is completed and back in the shop, it’s time to install the heads and reassemble the engine before installing it in the truck. Then, there are lots of things to reconnect, and some additional upgrades that can be made too. But that’s a story for a different issue. Stay tuned.

SOURCES:

ARP Automotive Racing Products

805.826.3045

Arp.Bolts.com

Domestic Diesel

909.627.0500

DomesticDieselshop.com

L&R Automotive Supply Co.

562.802.0443

InrEngine.com

MAHLE Motorsports

MAHLE.com

FREQUENTLY ASKED QUESTIONS

What components are included in the Motorcraft engine rebuild overhaul kit?

If you’re wondering what components are included in a comprehensive 7.3 engine rebuild overhaul kit, the list is extensive and designed to ensure a complete rebuild using Original Equipment Manufacturer (OEM) parts.

Here’s what you can expect:

Engine Essentials:
- Pistons
- Piston rings
- Low-pressure oil pump
Gaskets and Seals:
- Full set of gaskets, seals, and o-rings
- Injector gaskets, seals, and o-rings
- Oil cooler and its gaskets
- Head gaskets
Bearings:
- Cam bearings
- Rod bearing set
- Main bearing set
Valves and Plugs:
- Valve stem seals
- Glow plugs
Additional Components:
- Oil filter
- Instruction sheet
- Identification guide

This kit essentially arms you with all the necessary parts to rejuvenate your engine, ensuring every critical component is addressed.

What is the purpose of the Sealed Power 1885M Camshaft Bearing Set?

The Sealed Power 1885M Camshaft Bearing Set is engineered to enhance the performance and longevity of your 7.3 Powerstroke engine, manufactured between 1994 and 2003. This set plays a critical role in reducing friction between moving parts within the engine, which is essential for maintaining smooth operation.

Key Benefits:

Minimized Wear and Tear: These bearings provide a durable surface that minimizes friction, reducing wear and tear on the camshaft.
Improved Engine Efficiency: By lowering resistance, the bearings contribute to better fuel efficiency and overall engine performance.
Extended Engine Life: A well-functioning camshaft bearing set can significantly extend the lifespan of your engine by protecting it from unnecessary damage.

Why Choose This Bearing Set?

Crafted from high-quality materials, the Sealed Power bearings are designed to withstand extreme conditions, making them a reliable choice for those seeking to maintain their vehicle’s peak performance. Whether you’re a DIY enthusiast or a professional mechanic, investing in a top-quality camshaft bearing set is a smart decision for ensuring the health and efficiency of your engine.

What is the Clevite MS-2034P P-Series Main Bearing Set used for?

Understanding the Use of the Clevite MS-2034P P-Series Main Bearing Set

The MS-2034P P-Series Main Bearing Set is a crucial component for the engine’s long-term reliability and performance. It’s specifically designed for use in the Ford 7.3L Powerstroke engines produced from 1994 to 2003.

Key Functions:

Optimal Engine Performance: These bearings help maintain the precise alignment of the crankshaft, ensuring the engine operates smoothly.
Durability and Longevity: Engineered to withstand the demanding conditions of high-load applications, they offer enhanced durability that keeps your engine running efficiently over time.
Reduced Friction: By minimizing friction between moving parts, this bearing set helps in increasing overall engine efficiency.

Utilizing these bearings is vital for anyone looking to maximize the lifespan and performance of their vehicle’s engine, making it an essential part of the maintenance process for older Ford models.

What does the Clevite SH-1092S Camshaft Bearing Set include?

What’s Included in the SH-1092S Camshaft Bearing Set?

Revamp your 1994-2003 Ford 7.3L Powerstroke engine with the SH-1092S Camshaft Bearing Set. This comprehensive set is designed to enhance your engine’s performance by providing essential components for a successful rebuild.

Key Components:

Quality Bearings: Each set comes with high-quality bearings that ensure smooth camshaft operation and longevity.
Precision Engineering: The bearings are crafted with precision, providing a perfect fit for your engine and minimizing wear and tear.

Benefits:

Enhanced Performance: Reduces friction and improves the overall efficiency of your engine.
Reliable Construction: Built to withstand extreme conditions, offering durability and reliability on the road.

Make sure your engine rebuild is a success with the reliable components included in the SH-1092S Camshaft Bearing Set!

What warranty benefits come with using original equipment engine overhaul kits?

Unlocking Warranty Benefits with Original Equipment Engine Overhaul Kits

Choosing original equipment engine overhaul kits offers significant benefits, particularly in terms of warranty coverage. These kits help extend the life of your diesel engine while ensuring peace of mind with a comprehensive warranty package. Here’s what you gain:

Enhanced Engine Longevity: Maximize the lifespan of your engine components, knowing they are backed by a reliable warranty.
Comprehensive Coverage: Enjoy protection against unexpected repairs and replacements, alleviating concerns over potential future costs.
Competitively Structured: Benefit from a warranty that stands out in the market, providing you with excellent coverage compared to generic alternatives.

Investing in these kits not only bolsters engine performance but also secures a more robust warranty—offering both durability and assurance.

How does the cost of a rebuild kit compare to a rebuilt or used engine?

Comparing Costs: Rebuild Kit vs. Rebuilt or Used Engine

When deciding between rebuilding an engine yourself and purchasing a rebuilt or used engine, cost is a significant factor. Opting for a rebuild kit can offer substantial savings compared to the price of a pre-rebuilt or pre-owned engine.

Rebuild Kit Advantages

Cost-Effective Solution: Rebuild kits typically provide all the necessary components to refurbish your existing short block at a fraction of the price you’d pay for a complete rebuilt engine.
Original Equipment Quality: Many kits offer parts that match your engine’s original specifications, ensuring reliability and performance.

Financial Considerations

Rebuilt Engine: Often, a rebuilt engine is more expensive due to the labor and expertise involved in the process of disassembly, inspection, and reassembly.
Used Engine: While less costly than a rebuilt engine, used engines carry the risk of unknown wear and tear and reduced lifespan, potentially leading to additional expenses down the line.

By choosing a rebuild kit, you can save money while maintaining control over the repair quality, provided you have the skills to perform the rebuild. This option empowers vehicle owners to effectively manage engine restoration without breaking the bank.

What related products are available for rebuilding a Ford 7.3L Powerstroke engine?

Here you see the two types of OEM piston rods used in the 7.3L Ford diesel engines. On the left is one of the later model forged rods with cap studs. On the right is a powdered metal rod that uses rod bolts. The forged rods are preferable. The bolt-style rods have been tagged as “crack rods” by Ford diesel enthusiasts, as they tend to crack on the bolt interface when the stock bolts stretch. ARP offers a rod bolt kit for this type of rod, which greatly lessens this problem. The forged rods are still preferred, but your motor might not come with them.
Derek Ranney, manager and co-owner of L&R Automotive, inspects the new MAHLE pistons before they’re installed in our 7.3L Ford diesel. L&R has been in business for 38 years and supplies engine parts as well as top-quality machine work for all types of engines.

A few upgrades were made, such as adding ARP main studs and an upgrade to the better quality 7.3L Ford factory forged rods. MAHLE pistons and rings were also installed by L&R.

For those looking to rebuild their 1994-2003 Ford 7.3L Powerstroke engine, several high-quality components are available to ensure durability and performance:

Main Bearing Set: Equip your engine with a reliable main bearing set. The Clevite MS-2034P P-Series offers top-notch engine bearings specifically designed for your engine model, ensuring a perfect fit and lasting performance.
Camshaft Bearing Set: Upgrade with the Clevite SH-1092S Camshaft Bearing Set, renowned for its durability and precision fit. This set is essential for a smooth running camshaft, a critical component in any engine rebuild.
Rod Bearing Options: When considering rod bearings, the Clevite CB-1633P P-Series is a solid choice. For those looking for alternatives, the Sealed Power 83810CPA Rod Bearing Set is another option, both crafted to withstand the demands of the 7.3L Powerstroke.
Additional Components: The Sealed Power 1885M Camshaft Bearing Set is another excellent selection, offering reliability and performance to complement your engine rebuild.

Each of these components plays a crucial role in the overall performance and longevity of your engine. Choosing the right parts is key to a successful rebuild, ensuring that your Ford 7.3L Powerstroke delivers the power and reliability you expect.

Are there any additional services or conveniences offered (e.g., delivery options)?

A convenient service offered is free delivery to your closest store when you order online.

How can I purchase these products?

These products can be purchased online, with options to add them to the cart or a wish list for future purchase consideration.

What brands are these products from?

These products are from reputable brands like Clevite and Sealed Power.

What are the prices of these products?

The prices for these products are as follows: the main bearing set is $162.28, the camshaft bearing set costs $39.19, and the rod bearing is priced at $119.00.

What specific products are available for rebuilding a Ford 7.3L Powerstroke engine?

Some available products for the 1994-2003 Ford 7.3L Powerstroke include the Clevite MS-2034P P-Series Main Bearing Set, the SH-1092S Camshaft Bearing Set, and the CB-1633P P-Series Rod Bearing.

What does the 7.3 Powerstroke engine rebuild kit include?

Here you see the two types of OEM piston rods used in the 7.3L Ford diesel engines. On the left is one of the later model forged rods with cap studs. On the right is a powdered metal rod that uses rod bolts. The forged rods are preferable. The bolt-style rods have been tagged as “crack rods” by Ford diesel enthusiasts, as they tend to crack on the bolt interface, when the stock bolts stretch. ARP offers a rod bolt kit for this type of rod, which greatly lessens this problem. The forged rods are still preferred, but your motor might not come with them.

The comprehensive 7.3 Powerstroke engine rebuild kit offers everything you need for a complete overhaul. Included in this kit are:

Pistons and Piston Rings: Essential for restoring compression and performance.
All Gaskets, Seals, and O-rings: Ensures no leaks in the engine system.
Injector Gaskets, Seals, and O-rings: For maintaining efficient fuel injection.
Low Pressure Oil Pump and Oil Cooler with Gaskets: Vital for engine cooling and lubrication.
Cam Bearings and Valve Stem Seals: To support smooth engine operation.
Head Gaskets, Rod Bearing Set, and Main Bearing Set: Key components for engine assembly.
Glow Plugs and Oil Filter: To ensure reliable starting and filtration.
Instructions Sheet and Identification Guide: For a seamless rebuild process.

Derek Ranney, manager and co-owner of L&R Automotive, inspects the new MAHLE pistons before they’re installed in our 7.3L Ford diesel. L&R has been in business for 38 years and supplies engine parts as well as top quality machine work for all types of engines.
After the refurbishing, the block is ready for reassembly. Here you see the camshaft being installed. Since this engine is for a shop truck, a stock profile camshaft was used. For more performance, you can look to the aftermarket for many different grind profiles.
Here you can see the piston oilers. These must be installed, and this is best done before the camshaft. Do not forget them if you’re doing the assembly work yourself.

For those aiming for enhanced performance, a few upgrades were made, such as adding ARP main studs and an upgrade to the better quality 7.3L Ford factory forged rods. MAHLE pistons and rings were also installed by L&R. This blend of high-quality components and expert assembly ensures your engine will run optimally for years to come.

Does the kit include parts related to fuel injection, like injector gaskets and seals?

Yes, it includes injector gaskets, seals, and o-rings, covering essential components of the fuel injection system.

Are there any guides or instructions included in the kit?

The kit comes with instructions and an identification guide sheet, which are invaluable for aiding the assembly process and ensuring proper installation.

Does the kit include specific engine components like the oil cooler or low-pressure oil pump?

Indeed, the kit provides both an oil cooler with the required gaskets and a low-pressure oil pump, crucial for maintaining engine performance.

Are all necessary seals and gaskets included?

Yes, the kit includes a full set of gaskets, seals, and o-rings, ensuring that you have all the necessary sealing components for a complete engine rebuild.

What components are included in the rebuild kit?

The rebuild kit contains numerous essential components, such as pistons, piston rings, a comprehensive set of gaskets, seals, and o-rings, along with bearings for the cam and rods. It also includes glow plugs and a low-pressure oil pump, among other parts.

What are the benefits of using genuine OEM parts in an engine rebuild kit?

Here you see the two types of OEM piston rods used in the 7.3L Ford diesel engines. On the left is one of the later model forged rods with cap studs. On the right is a powdered metal rod that uses rod bolts. The forged rods are preferable. The bolt-style rods have been tagged as “crack rods” by Ford diesel enthusiasts, as they tend to crack on the bolt interface, when the stock bolts stretch. ARP offers a rod bolt kit for this type of rod, which greatly lessens this problem. The forged rods are still preferred, but your motor might not come with them.

When it comes to rebuilding your engine, opting for genuine OEM parts has distinct advantages. These components not only ensure authenticity and quality but also provide a cost-effective alternative to purchasing a rebuilt or used engine. Genuine parts, like those found in OEM engine overhaul kits, are designed to fit seamlessly and function optimally within your engine, offering extended engine life and reliability.

Moreover, these kits often come with competitive warranties, adding an extra layer of security to your investment. Investing in OEM parts means you’re choosing components that are engineered to meet the high standards set by the original manufacturer, ensuring durability and performance.

By integrating these genuine parts into your rebuild, you’re not just fixing your engine; you’re revitalizing it with a commitment to quality and longevity. So whether you’re dealing with piston rods or any other component, the benefits of using OEM parts are clear: enhanced reliability, prolonged engine life, and peace of mind.

What additional benefits come with these components?

Ford’s competitive warranty accompanies these components, offering added assurance and value to the consumer.

How do these components affect the engine’s life?

By using genuine OE Ford components, owners can significantly extend the lifespan of their diesel engines.

What components are included in Ford Diesel Engine Overhaul Kits?

These kits consist of 100% genuine OE Ford components, ensuring high quality and compatibility with Ford diesel engines.

What is an affordable alternative to purchasing a rebuilt or used engine?

Original Equipment (OE) engine overhaul kits provide a cost-effective option for those looking to avoid the expense of buying rebuilt or used engines.