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 |
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 |
|
Replace engine air filter |
Inspect at oil change intervals, replace as required |
|
Flush/service engine cooling systems |
50,000 miles/48 months initially |
|
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
7.3 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 |
[3] |
|
SAE 10W-30 preferred in ambient temperatures between -10 to 30° F |
|||
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 |
[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) |
--- |
6 speed (ZF S6-650) |
|||
Transfer case fluid |
Motorcraft MERCON LV ATF (XT-10-QLVC) |
[6] |
|
Front differential gear oil |
Dana 50 TTB (F-250 only) |
SAE 80W-90 gear oil (synthetic preferred) |
--- |
Dana 60 |
SAE 80W-90 gear oil or SAE 90 hypoid gear oil (synthetic preferred) |
||
Rear differential gear oil |
Sterling 10.25, 10.50 |
SAE 75W-140 full synthetic gear oil |
[7] |
Dana 80 |
SAE 75W-90 full synthetic gear oil |
||
Dana 135 (F-550 only) |
SAE 80W-90 gear oil |
||
Limited slip additive |
Motorcraft XL-3 friction modifier |
||
Brake fluid |
Motorcraft PM-1 DOT 3 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 |
||
Engine oil fill cap |
Motorcraft EC-743 (Ford F3AZ-6766-B) |
|
Oil pan drain plug |
||
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 |
|
1999 - 2003 |
||
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 |
||
Thermostat |
1994 - 1995 |
|
1996 -2003 |
||
Thermostat housing gasket |
1994 - 1995 |
|
1996 -2003 |
Motorcraft RG602 (Ford F81Z-8255-AA) |
|
Radiator overflow/degas cap |
||
Upper radiator hose |
1994.5 - 1997 |
|
1999 - 2003 (single alt) |
||
1999 - 2003 (dual alt) |
||
Lower radiator hose |
1994 |
|
1995 - 1997 |
||
1999 - 2000 |
||
2001 (built before 4/29/01) |
||
2001 (built after 4/29/01) |
||
2002 - 2003 |
||
Block heater coil |
||
Cam position sensor (CPS) |
||
Exhaust backpressure sensor (EBP) |
Motorcraft DPFE3 (Ford 4C3Z-9J460-A) |
|
Exhaust backpressure sensor tube |
1994.5 - 1997 |
|
1997.5 - 1998 |
Ford F7TZ-9D477-AA |
|
1999 - 2003 |
||
Turbocharger up-pipe gasket |
1994.5 - 1997 |
|
1999 - 2003 |
||
Injector control pressure sensor (ICP) |
1994.5 - 1996 |
|
1997 - 2003 |
||
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) |
|