7.3L Power Stroke Power Recipes - Budget-Build

For $1,500, $2,500, $5,000, And $10,000 Budgets

Mike McGlothlin
Aug 1, 2009
Photographers: Mike McGlothlin
Photo 2/3   |   7 3l Power Stroke Power Recipes ford F250
For most of us, our trucks only get modified as far as our wallets allow them to. And, because we're not all on the same budget, we've included some bang-for-the-buck-type power recipes for your 7.3L Power Stroke in this issue. Keep in mind that when we began compiling these power-adding recipes, we also took into consideration reliability and longevity. The last thing we want you to do is blow up your truck, or spend all your time behind the wheel watching gauges. The following budget-build suggestions will give you good power increases, and allow you to keep towing and hauling with your Ford. Our suggestions aren't about making the most horsepower--they're about getting more power, diagnosing and addressing weak links, and making your truck last.
Photo 3/3   |   7 3l Power Stroke Power Recipes ford F350
We'll begin with '94 to '97 7.3L Power Strokes and progress through to 7.3L Super Duty engines. Budgets range from $1,500 to $10,000 for each International mill and include reasonably priced parts from reputable aftermarket companies. However, they do not include labor you might have to pay should you prefer a shop perform the modifications. Stay tuned for 6.0L and 6.4L Power Stroke power recipes, as well as Cummins and Duramax suggestions in the coming months.
$1,500 BUDGET
7.3L 1994 – 1997 (with E4OD automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Overboost Annihilator ITP Diesel Keeps overboost CEL off (boost fooler) $45 ITP Diesel Bean's Diesel Performance
Gauges Autometer Monitor EGTs, boost, transmission temps $305 Diesel Innovations Autometer
Shift Kit (Tugger kit) TransGo Firm up shifts, reduce slippage $110 Sun Coast Converters
Horsepower Range (at the wheels): 230 – 260 hp Weak link: Torque converter TOTAL: $1,309.55 - $1,384.55
7.3L 1994 - 1997 (WITH ZF FIVE-SPEED)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Overboost Annihilator ITP Diesel Keeps overboost CEL off (boost fooler) $45 ITP Diesel Bean's Diesel Performance
Turbo (exhaust housing) Bean's Diesel Performance Small 1.0 A/R turbine housing, quicker spool up $155 Bean's Diesel Performance
Gauges Autometer Monitor EGTs, boost, transmission temps $260 Diesel Innovations Autometer
Horsepower Range (at the wheels): 230 – 260 hp Weak link: Clutch TOTAL: $1,309.55 - $1,384.55
$2,500 BUDGET
7.3L 1994 - 1997 (with E4OD automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Torque Converter John Wood (6.0L) Precision Industries Triple-disc, more efficient $750 - ${{{900}}} John Wood Automotive Precision Industries
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Overboost Annihilator ITP Diesel Keeps overboost CEL off (boost fooler) $45 ITP Diesel Bean's Diesel Performance
Gauges Autometer Monitor EGTs, boost, transmission temps $305 Diesel Innovations Autometer
Accumulator Body Kit BD Diesel Firmer shifts, reduce slippage $237.50 Innovative Diesel Performance
Horsepower Range (at the wheels): 230 – 260 hp Weak link: Transmission internals TOTAL: $2,187.05 - $2,412.05
$2,500 BUDGET
7.3L 1994 - 1997 (with ZF Five-speed)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Clutch South Bend Con O five-speed, 350hp clutch $650 Bean's Diesel Performance Swamp's Diesel Performance
Overboost Annihilator ITP Diesel Keeps overboost CEL from coming on (boost fooler) $45 ITP Diesel
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps $260 Diesel Innovations, Autometer
Horsepower Range (at the wheels): 230 – 260 hp Weak Link: Clutch TOTAL: $1,804.55 - $1,879.55
$5,000 BUDGET
7.3L 1994 - 1997 (with E4OD automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Stage 1 Injectors Full Force Diesel Remanufactured, inspected ${{{850}}} - $875 Total Diesel Performance Bean's Diesel Performance
Intercooler Banks Cooled intake temps, reduced EGTs $1,487 Total Diesel Performance
Overboost Annihilator ITP Diesel Keeps overboost CEL from coming on $45 ITP Diesel
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps $305 Diesel Innovations, Autometer
Torque Converter John Wood (6.0L) Precision Industries Triple-disc, more efficient $750 - ${{{900}}} John Wood Automotive Precision Industries
Accumulator Body Kit BD Diesel Firmer shifts, reduce slippage $237.50 Innovative Diesel Performance
Deep Transmission Pan B&{{{M}}} More fluid capacity, better cooling $180 Innovative Diesel Performance
Horsepower Range (at the wheels): {{{300}}} - 350 hp Weak links: Transmission internals, stock turbo TOTAL: $4,704.05 - $4,954.05
7.3L 1994 - 1997 (with ZF Five-speed)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Stage 1 Injectors Full Force Diesel Remanufactured, inspected $850 - $875 Total Diesel Performance Bean's Diesel Performance
Intercooler Banks Cooled intake temps, reduced EGTs $1,487 Total Diesel Performance
Overboost Annihilator ITP Diesel Keeps overboost CEL from coming on $45 ITP Diesel
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps $260 Diesel Innovations, Autometer
Clutch South Bend Con O five-speed, better pressure plate $650 Bean's Diesel Performance Swamp's Diesel Performance
HPOP (Adrenaline) Diesel Site 17-degree pump, more oil flow for injectors $469 Diesel Site
Horsepower Range (at the wheels): 300 - 350 hp Weak link: stock turbo (addressed in $10,000 budget) TOTAL: $4,610.55 - $4,710.55
$10,000 BUDGET
7.3L 1994 - 1997 (with E4OD automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Stage 2 Injectors Full Force Diesel Remanufactured, inspected $1,500 Total Diesel Performance
Intercooler Banks Cooled intake temps, reduced EGTs $1,487 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations, Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps $305 Diesel Innovations Autometer
Transmission Brian's Truck Shop Built, triple-disc converter, shift kit, etc. $4,000 - $4,{{{300}}} John Wood Automotive Sun Coast Converters
Turbo (D66) BDP Dominator 66, 40-psi efficiency range $1,125 Bean's Diesel Performance
HPOP (Adrenaline) Diesel Site 17-degree pump, more oil flow for injectors $469 Diesel Site
Horsepower Range (at the wheels): 380 – 420 hp Weak Link: Transmission TOTAL: $9,735.55 - $10,110.55
7.3L 1994 - 1997 (with ZF Five-speed)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake Tymar Freer-flowing air intake $159 Bean's Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit, no tip $290.55 Bean's Diesel Performance Empire Diesel Performance
Stage 3 Injectors Full Force Diesel Remanufactured, inspected hybrids $2,450 Bean's Diesel Performance
Intercooler Banks Cooled intake temps, reduced EGTs $1,487 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations, Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps $260 Diesel Innovations, Autometer
Clutch South Bend Con OFE five-speed, 450hp clutch ${{{900}}} Bean's Diesel Performance Swamp's Diesel Performance
Turbo (H2E, modified) Hypermax 400-plus-hp turbo, flows 1,{{{100}}} cfm $2,999 Bean's Diesel Performance
HPOP (Adrenaline) Diesel Site 17-degree pump, more oil flow for injectors $469 Diesel Site
Horsepower Range (at the wheels): 450-plus hp Weak Link: Head bolts TOTAL: $9,414.55 - $9,489.55
SUPER DUTY
$1,500 BUDGET
7.3L 1999-1/2 - 2003 (with 4R100 automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake AFE Freer-flowing air intake $187.25 Innovative Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit with tip $360 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Overboost Annihilator ITP Diesel Keeps overboost CEL from coming on (boost fooler) $45 ITP Diesel
Gauges Autometer Monitor EGTs, boost, transmission temps $290 Bean's Diesel Performance
Shift Kit (Tugger kit) TransGo Firm up shifts, reduce slippage $110 Sun Coast Converters
Horsepower Range (at the wheels): 280 – 310 hp Weak link: Torque converter TOTAL: $1,392.25 - $1,467.25
$1,500 BUDGET
7.3L 1999-1/2 - 2003 (with ZF Six-speed)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake AFE Freer-flowing air intake $187.25 Innovative Diesel Performance
Exhaust MBRP 4-inch with 3-inch downpipe, single exit with tip $360 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Overboost Annihilator ITP Diesel Keeps overboost CEL from coming on (boost fooler) $45 ITP Diesel
Gauges Autometer Monitor EGTs, boost, transmission temps ${{{240}}} Bean's Diesel Performance
Horsepower Range (at the wheels): 280 – 310 hp Weak link: Clutch TOTAL: $1,232.25 - $1,307.25
$2,500 BUDGET
7.3L 1999-1/2 - 2003 (with 4R100 automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake S&B Freer-flowing air intake $269 S&B
Exhaust MBRP 4-inch with downpipe, single exit with tip $360 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Overboost Annihilator ITP Diesel Keeps overboost CEL from coming on (boost fooler) $45 ITP Diesel
Gauges Autometer Monitor EGTs, boost, transmission temps $290 Bean's Diesel Performance
Torque Converter John Wood (6.0L) Precision Industries Triple-disc, more efficient $750 - ${{{900}}} John Wood Automotive Precision Industries
Accumulator Body Kit BD Diesel Firmer shifts, reduce slippage $237.50 Innovative Diesel Performance
Horsepower Range (at the wheels): 280 – 310 hp Weak link: Transmission internals TOTAL: $2,351.50 - $2,576.50
7.3L 1999-1/2 - 2003 (with ZF Six-speed)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake S&B Freer-flowing air intake $269 S&B
Exhaust MBRP 4-inch with downpipe, single exit with tip $360 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Overboost Annihilator ITP Diesel Keeps overboost CEL from coming on (boost fooler) $45 ITP Diesel
Gauges Autometer Monitor EGTs, boost, transmission temps ${{{240}}} Bean's Diesel Performance
Fuel System Diesel Innovations Regulated return kit, efficient fuel flow $449 Diesel Innovations
Turbo Housing Bean's Diesel Performance 1.0 A/R wastegated upgrade, lower EGTs $249 Bean's Diesel Performance
Swisher compressor wheel Diesel Innovations Reduce turbo surge $87 Diesel Innovations
Horsepower Range (at the wheels): 280 – 310 hp Weak link: Clutch TOTAL: $2,099 - $2,174
$5,000 BUDGET
7.3L 1999-1/2 - 2003 (with 4R100 automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake S&B Freer-flowing air intake $269 S&B
Exhaust MBRP 4-inch with downpipe, single exit with tip $360 Total Diesel Performance
Stage 2 Injectors Full Force Diesel Remanufactured, inspected $1,500 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations, Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps $290 Bean's Diesel Performance
Accumulator Body Kit BD Diesel Firmer shifts, reduce slippage $237.50 Innovative Diesel Performance
Torque Converter John Wood (6.0L) Precision Industries Triple-disc, more efficient $750 - ${{{900}}} John Wood Automotive Precision Industries
Fuel System AirDog 150-gph fuel pump $499 Xtreme Diesel
Turbo Housing Bean's Diesel Performance 1.15 A/R non-wastegated, lower drive pressure $445 Bean's Diesel Performance
Horsepower Range (at the wheels): 370 – 420 hp Weak links: Transmission internals, EGTs when towing heavy TOTAL: $4,750.50 - $4,975.50
7.3L 1999-1/2 - 2003 (with ZF Six-speed)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake S&B Freer-flowing air intake $269 S&B
Exhaust MBRP 4-inch with downpipe, single exit with tip $360 Total Diesel Performance
Stage 2 Injectors Full Force Diesel Remanufactured, inspected $1,500 Total Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations, Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps ${{{240}}} Bean's Diesel Performance
Clutch South Bend Con OFE, 450hp clutch $900 Bean's Diesel Performance
        Swamp's Diesel Performance
Fuel System AirDog 150-gph fuel pump $499 Xtreme Diesel
Turbo Housing Bean's Diesel Performance 1.15 A/R non-wastegated, lower drive pressure $445 Bean's Diesel Performance
Swisher compressor wheel Diesel Innovations Reduce turbo surge $87 Diesel Innovations
Horsepower Range (at the wheels): 370 – 420 hp Weak links: Factory turbo, EGTs when towing heavy TOTAL: $4,700 - $4,775
$10,000 BUDGET
7.3L 1999-1/2 - 2003 (with 4R100 automatic)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake S&B Freer-flowing air intake $269 S&B
Exhaust MBRP 4-inch with downpipe, single exit with tip $360 Total Diesel Performance
Stage 3 Injectors Full Force Diesel Remanufactured, inspected hybrids $2,499 Bean's Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance, DP-Tuner Swamp's Diesel Performance Diesel Innovations, Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps $290 Bean's Diesel Performance
Transmission Brian's Truck Shop John Wood Automotive Sun Coast Converters Built, triple-disc converter, shift kit etc. $4,000 - $4,{{{300}}} Brian's Truck Shop John Wood Automotive Sun Coast Converters
Fuel System AirDog 150-gph fuel pump $499 Xtreme Diesel
Turbo Garrett GTP38R, quick spool up, wastegated $1,750 Swamp's Diesel Performance
Horsepower Range (at the wheels): 460 – 500 hp Weak link: Late ’01 to ’03 Power Strokes had powdered metal connecting rods, which have proven unable to handle much more than 450 hp. We recommend the above mods but suggest conservative tuning with your chip purchase.   TOTAL: $10,067 - $10,442
$10,000 BUDGET
7.3L 1999-1/2 - 2003 (with ZF Six-speed)
Modification: Company(s): Reason Or Details: Price: Vendor:
Cold-Air Intake S&B Freer-flowing air intake $269 S&B
Exhaust MBRP 4-inch with downpipe, single exit with tip $360 Total Diesel Performance
Stage 3 Injectors Dynomite Diesel Performance New injectors $3,250 Dynomite Diesel Performance
Chip TS Performance, Moates Custom-tuned six-position chip, or F5 $400 - $475 Total Diesel Performance DP-Tuner Swamp's Diesel Performance Diesel Innovations Brian’s Truck Shop
Gauges Autometer Monitor EGTs, boost, transmission temps ${{{240}}} Bean's Diesel Performance
Clutch South Bend Con FE, 550hp clutch $1,000 Bean's Diesel Performance Swamp's Diesel Performance
Fuel System AirDog 150-gph fuel pump $499 Xtreme Diesel
Turbo Garrett GTP38R, quick spool up, wastegated $1,750 Swamp's Diesel Performance
High-Pressure Terminator Engineering Twin HPOP (utilizes stock HPOP) $1,995 Diesel Innovations
Oil Pump        
Horsepower Range (at the wheels): 460 – 500 hp Weak link: Late ’01 – ’03 Power Strokes had powdered metal connecting rods, which have proven unable to handle much more than 450 hp. We recommend the above mods but suggest conservative tuning with your chip purchase. Also important, the factory head bolts will be a weak link from the 450hp range and beyond, so head studs would be next on our list.   TOTAL: $9,763 - $9,838

Sources

Sun Coast Converters
Fort Walton Beach, FL 32547
800-868-0053
www.suncoastconverters.com
TS Performance
Bowling Green, KY 42101
270-746-9999
www.tsperformance.com
MBRP Performance Exhaust
N/A, AK
888-636-7223
www.mbrpautomotive.com
Empire Diesel Performance
Dubuque, IA 52002
563-580-0755
www.empiredieselperformance.com
Advanced Flow Engineering
Corona, CA 92879
951-493-7100
www.afepower.com
S&B Filters
Ontario, CA 91761
800-358-2639
www.sbfilters.com
South Bend Clutch
Mishawaka, IN 46545
800-988-4345
www.southbendclutch.com
Dynomite Diesel Performance
Monroe, WA 98272
760-794-5732
www.dynomitediesel.com
Transgo
El Monte, CA 91733
626-443-7451
http://www.transgo.com/
John Wood Automotive
Holtville, CA 92250
760-356-9421
www.jwtt.com
Brian's Truck Shop
Lead Hill, AZ 72544
870-422-3673
www.brianstruckshop.com
DP-Tuner
Hoschton, GA 30548
828-221-0076
www.dp-tuner.com
Total Diesel Performance
Fort Worth, TX 76131
817-932-5078
www.totaldieselperformance.com
Precision Industries
Whiteville, TN 38075
731-254-0055
http://www.converter.com
Hypermax Engineering
Gilberts, IL 60136
http://www.gohypermax.com
Bean's Diesel Performance
615-563-7800
http://www.beansdieselperformance.com
Innovative Diesel Performance
866-642-7844
http://www.innovativediesel.com
Full Force Diesel
615-962-8291
http://www.fullforcediesel.com
ITP Diesel
www.itpdiesel.com
Diesel Innovations
www.dieselinnovations.com
Diesel Site
www.dieselsite.com
Swamp's Diesel Performance
www.swampsdiesel.com
Terminator Engineering
www.terminatorengineering.com
Xtreme Diesel
www.xtremediesel.com
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