7.3L Power Stroke Service Information

Service Intervals

Replace engine oil & oil filter

5,000 miles/6 months under normal operating conditions
3,000 miles/3 months under severe duty conditions

Replace fuel filter

15,000 miles

Replace engine air filter

30,000 miles/30 months or as necessary

Flush engine cooling system

50,000 miles/48 months initially followed by 30,000 miles/36 month intervals

Replace automatic transmission fluid & filter

30,000 miles (E4OD normal, 4R100 normal & severe)
21,000 miles for E4OD transmissions under severe duty conditions

Replace manual transmission fluid

60,000 miles

Replace transfer case fluid

60,000 miles

Replace front differential fluid (4x4)

100,000 miles under normal operating conditions
30,000 miles under severe duty conditions
Drain and replace oil immediately if axle is submerged in water

Replace rear differential fluid

100,000 miles under normal operating conditions
30,000 miles under severe duty conditions
Drain and replace oil immediately if axle is submerged in water

Part numbers listed below are for Super Duty trucks; some parts may vary for E-Series and Excursion applications

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 F5TZ-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)

Oil & Fluid Specs

Engine oil

15W-40

Acceptable viscosity in ambient temps > 10° F
Preferred viscosity in ambient temps > 30° F

10W-30

Acceptable viscosity in ambient temps -10 to 90° F
Preferred viscosity in ambient temps -10 to 30° F

5W-30

Acceptable viscosity in ambient temps < 30° F

0W-30

Acceptable viscosity in ambient temps < 0° F

Engine coolant

Ford/Motorcraft VC-5 concentrated engine coolant mixed 50/50 w/ distilled water
Note - coolant ratio can be increased to 60% if protection from extreme cold is required.
Do not exceed a 60/40 (60% coolant concentrate, 40% distilled water) under any circumstances.

Automatic transmission fluid

MERCON V full synthetic ATF (replaces defunct MERCON spec, 4R100 & E4OD transmissions)

Manual transmission fluid

ZF S5-42/S5-47 (5 spd)

MERCON V full synthetic ATF (replaces defunct MERCON spec)

ZF S6-650 (6 spd)

MERCON V full synthetic ATF (replaces defunct MERCON spec)

Transfer case fluid

Motorcraft XL-12 transfer case fluid

Front differential fluid

Dana 50 (IFS)

SAE 80W-90 gear oil (synthetic preferred)

Dana 60

SAE 80W-90 gear oil or SAE 90 hypoid gear oil (synthetic preferred)

Rear differential fluid

Sterling 10.25"/10.50"

SAE 75W-140 full synthetic gear oil
(limited slip differential may require friction modifier Motorcraft XL-3)

Dana 80

SAE 75W-90 full synthetic gear oil
(limited slip differential may require friction modifier Motorcraft XL-3)

Dana 135 (F-550 only)

SAE 80W-90 gear oil
(limited slip differential may require friction modifier Motorcraft XL-3)

Oil & Fluid Capacities

Fluid capacities are nominal - always fill to proper level on dipstick or to fill plug level as applicable.
All measurements in U.S. quarts ("qts") and/or pints ("pts"), NOT Imperial.

Engine oil

15 qts w/ filter

Engine cooling system

1994 - 1997

7.24 gallons, 29 qts

1999 - 2003

8.2 gallons, 32.75 qts

ZF S5-47 5 spd transmission

3.4 qts

ZF S6-650 6 spd transmission

5.8 qts

E4OD 4 spd transmission

4x2

15.7 qts

4x4

16.2 qts

4R100 4 spd transmission

17.1 - 17.7 qts

BW1356 transfer case

2.0 qts

Dana 50 IFS front differential

1.9 qts (F-250 only)

Dana 60 front differential

2.9 qts

Sterling 10.25" rear differential

3.75 qts

Sterling 10.50" rear differential

3.45 qts

Dana 80 rear differential

4.15 qts

Dana 135 rear differential

12.25 qts (F-550 Super Duty only)