Ok, purchased a 1995 7.3 with an E4OD, around a 75,000. Standard cab, F250 4X4 a couple years ago. Ran good for about 30,000, just a turbo oil leak and a cam sensor.

This truck has had three flexplate installed and they cracked in less than 3000 miles. The trans was rebuild, new flexplate, new torque converter, ran less than 3000 miles, cracked the flexplate.
Took it to ford, had a ford rebiult trans and a new flex plate, 5000 and the same thing....
Engine endplay is fine, oil pressure and everything else looks fine.

Any ideas?

 

Trade it in on a Dodge I guess.

Ron

 

davisrats suggestions like that will not earn you any friends or respect here. If you dont like Ford trucks may I suggest you keep your mouth shut.

 

There was a TSB put out about this problem. Main cause was machining of the rear gear cover (machined cast aluminum part between engine and trans). The bad covers were machined off parallel and caused extra load on the flexplate. The fix was to change the gear cover AND the following p[arts (since they may be damaged after flexplate failure): crank spacer, flexplate reinforcing plate, crank bolts. Since your vehicle has 75,000 miles omn it, then it is possible that the gear cover is OK. These failures are usually low mileage. To tell if the gear cover is OK or not, remove it and use micrometers to measure the thickness of the cover all the way around. The measurements should all be well within .010" of each other. I've seen bad ones which were any where from .015" to .118" different. If your's measures OK, then I suspect that the other parts (crank spacer) was damaged during one of the failures. The flexplate for the 7.3 is pretty durable and doesn't really have any warranty history other than special causes like the gear cover issue.

 

Does anyone have this TSB or the TSB number, the Ford dealer says he can't find it.

Thanks

 

The original TSB was written against 1999 and prior PSD, however, it was supposed to have been updated to cover all 7.3L applications. The original TSB number is: 99-23-6.

 

Thanks for the info.

 

Let me know if this fixs your problem.

 

The truck is at the Ford dealer, it was back together, they claimed there was no TSB, after presenting them the TSB they disasembled the truck and now say there are parts on order.

Thanks again, will keep you posted.

 

Well the truck has been out of the stealership for a couple weeks now. About 1800 miles on it and so far so good.

 

I know it can be nerve racking, waiting and hoping it doesn't fail again. Keep us posted on your success. By the way, what parts did they replace? The TSB names several parts to be checked and/or replaced.

 

The crank spacer, flex-plate, engine spacer/housing, bolts etc were changed.
5500 mile so far, fingers crossed...

Thanks for the help

 

well it died again. same thing cracked flex plate. Too bad it was a great truck.

 

Put a 5 speed. In and keep the truck!

 

Sounds like the crankshaft is machined crooked or something. Everything else has been changed several times.