1999-2003 Ford Super Duty & Excursion 7.3L PSD TECH FOLDER
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1999-2003 Ford Super Duty & Excursion 7.3L PSD TECH FOLDER
If you would like to suggest a document or link for the "7.3L PSD Tech Folder", please send Y2KW57 a PM and it will be considered.
As you are reading through the links below, keep in mind some subjects may not fit perfectly into a category.
Please scroll completely through the links, down to the "Misc Information & Modifications" section before moving on.
***Some of the information below resides on the Excursion sub-forum, but is relevant to the 7.3L PSD.***
Excursion, FTE & Super Duty Articles
Ford Motor Company Misc Information
- E99 - L99 Update Information
- Coffee Table Books
- Connector Catalog
- FordEtis
- Ford Owner Manuals SiteMap (30 year lookback)
- Ford Owner Manuals Interactive (10 year lookback)
- Parts Catalog
Safety First
- Raising & Supporting Super Duty Vehicles
- Placeholder
Decoders
Diagnostics
- PowerStroke Diagnostics
- PSD Diagnosis On The Cheap -1
- PSD Diagnosis On The Cheap - 2
- PID Charting Tool
- PID Charting Tool For TP Instructions - Video
- PID's Explained
- PID's Worth Looking At
- Quick Reference Guide
- Engine DTC's
- 2002 PCED OBDII DTC List
- New Generation Star Tester Hookup
- Reference Voltage Test (requires removal of PCM, and ideally a 104 Pin BOB)
- Unable to Activate Self Test w/Scan Tool, DTC 1502
- AutoEnginuity
- CCT, CRV and PERDEL Explained
- OBDII Codes
- OBD Comparison Table
- Pinpoint Test Index from PC/ED
- 2000 Injection Control Pressure ICP Sensor Introduction
- 2000 Injection Control Pressure ICP Pinpoint Tests
- 2000 Injection Pressure Regulator IPR Pinpoint Tests
- No Start Diagnostic Chart - Ford Created
- No Start Flow Chart - FTE Created
- Cruise Control/Speed Control Diagnosis
- 2002 Exhaust Back Pressure Regulator (EPR) DTC P0475
- Vibration Diagnosis
FORScan
- FORScan Instructions - PC
- FORScan Lite Instructions - Android
- FORScan Lite Instructions - iOS
- FORScan Data Log Conversion
- PERDELs via Forscan
- Cruise Control/Speed Control Forscan function test
- Speedometer Calibration Using Forscan - Thread
- Speedometer Calibration Using Forscan - Video
- FORScan + FORScan Lite: Class Tutorial Q&A
Data Display Overlay Sync Software For Video
- DashWare: Setting Up Profile, Creating Gauges, Modifying Data Log
- Placeholder for RaceRender
- Placeholder for TrackVision
- Placeholder for TraqStudio
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MODULES
PCM - PowerTrain Control Module
- PCM Probe & Back Probe
- PCM Wiring Diagram (Powertrain Control System - 2002)
- Old and New Methods of Hydra Mounting
IDM - Injector Driver Module
- IDM - 42 Pin - UVCH Map
- IDM Replacement & Testing
- IDM Wire Map
- IDM Electronic Feedback DTC P1668 & P1670 (2002)
GEM - General Electrical Module
- GEM DTC Identification
- GEM DTC's
- GEM PID's
- GEM Information
- GEM Pinpoint Test
- GEM Wiring Diagram
- 2001 GEM & Under Dash Fuse Box Removal & Disassembly for Cleaning & Restoration from water damage
HEIC - Hybrid Electronic Instrument Cluster
- HEIC Hybrid Electronic Instrument Cluster (2002-2003) Diagnosis
- HEIC Fuel Gauge Trip Computer Tank Selector Valve Block Diagram
VSM - Vehicle Security Module
SRS - Supplemental Restraint System Module
- 2000 Wire Diagram 046-004 Air Bag Restraint System Pickup
- 2000 Wire Diagram 044-002 Air Bag Sliding Switch Clockspring
ABS - AntiLock Brake System Module
.
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ELECTRICAL
Wiring Diagrams
- Wiring Diagram (Main OEM Harness)
- 2000 Wiring Diagram Accelerator Position Sensor
- 5v Reference Pinpoint Test
- 42 Pin Connector Map
- 7-Way Trailer Plug Wiring - 1
- 7-Way Trailer Plug Wiring - 2
- Alternator (Dual) Wiring Diagrams
- CPS/CMP Pinpoint Test
- Headlight Wiring Color Code
- Instrument Cluster Pinpoint Test 2002
- Overhead Console Display Repair
- Starting System Wiring Diagram (2002)
- 2000 Wire Diagram 090-002 Turn Stop Hazard Lamps Pickup
- 2000 Wire Diagram 149-007 Component Testing Multi-function Switch
- 2001 Wire Diagram 102-02 Overhead Console
Alternator
- Alternator & Charging System Checks
- Alternator Diagnosis & Testing
- Alternator (Dual) Wiring Diagrams
- Alternator Internal Regulator R&R
- Alternator (Dual) Wiring Diagrams
- 6G Alternator Rebuild
- Quick-Start Alternator Install
Batteries
Parasitic Drain Diagnosis
- Placeholder (Under Development) - Consolidated Content
- Placeholder (Under Development) - Anecdotal Reports of Culprits
- Placeholder (Under Development) - Individual Threads in Forum Archives
Starter
- Starting System Wiring Diagram (2002)
- 6.7 Starter Modification
- 6.7 Starter Installation in 7.3
- Denso High Torque Starter - Video
Ignition Switch
- Ford Ignition Slide Switch (Not Key Cylinder) Testing and Dissection
- Engine Disabler
- Quick Easy Immobilizer (by F350Towing)
Glow Plugs, Glow Plug Relay, Glow Plug Control Module
- Glow Plug Control Module Pinpoint Test
- Glow Plug System Pinpoint Test
- Glow Plug Pull - Video
- Glow Plug Relay Info & Testing
- Glow Plug Relay (Trombetta 684-1241-212) Install
- Glow Plug Relay Relocation Mod
Outside Rear-View Towing Mirrors Electrical
- Mirror Wiring Harness Adapter
- Adding Power To Turn Signal Mirrors
- 1999-2003 F-250/350 Super Duty Retrofit POWER Tow Mirror Wiring PROJECT OVERVIEW pdf
- 1999-2003 F-250/350 Super Duty Retrofit POWER Tow Mirror Wiring COLOR CODES & CONNECTORS pdf
- 1999-2003 F-250/350 Super Duty Retrofit POWER Tow Mirror Wiring DIAGRAMS & SWITCH TESTING pdf
Miscellaneous Electrical
- 3rd Brake Light/Bed Illumination Mod
- 5v Reference Pinpoint Test
- 42 Pin Connector Map
- 7-Way Trailer Plug Wiring - 1
- 7-Way Trailer Plug Wiring - 2
- Accessory Delay Intermittent Failure Fix
- Auxiliary Interior Fuse Block
- Complete LED Swap
- CPS/CMP Pinpoint Test
- Headlight Wiring Color Code
- Instrument Cluster Pinpoint Test 2002
- LED Under Hood Lighting Upgrade
- Overhead Console Display Repair
- VSM Teardown
- Wiring Diagram (Main OEM Harness)
- Auxiliary Reverse Lamps in Bumper Mounted Steel Buckets, w/SPDT Switch For On/Reverse and On/Manual Operation - BigHorn2
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ENGINE
General Engine & Engine Compartment
- 6637/Donaldson Blue Air Filter install
- 7.3L Engine Removal Procedure (2000)
- 7.3L Engine Removal Procedure (2002)
- 7.3L Engine Installation Procedure (2002)
- AIH Delete Code Eliminator
- Coolant Flush (Gooch Method)
- Coolant Flush (SkySkiJason Method)
- Cylinder Compression Test Procedure
- Dual Alternator Belt Flutter Fix
- EBPV Operation Parameters
- Engine Coolant Sensors (ZF6)
- Engine Valley Sensors & Fittings - 1
- Engine Valley Sensors & Fittings - 2
- Engine Valley Sensors & Fittings - 3
- Exhaust Manifold Re-Seal
- Serpentine Belt Routing
- Valley Drain Tube
- Valve Cover Connector Pigtail
- Valve Spring Compression Tool (DIY)
Engine Oil and Oil Systems
HPOP - High Pressure Oil Pump, Lines, Reservoir, & Related
- HPOP & Injector O-Ring Test Parts List
- HPOP & Reservoir Draining Possible Fixes
- What's the Current Recommended HPOP?
- IH DT466 HPOP Rebuild Photos
- High Pressure Oil Pump and Cylinder Head Dead Head Testing
LPOP - Low Pressure Oil Pump and Oil Flow
Oil Cooler
Oil Filter
Oil Specifications & Recommendations
Turbocharger
- 2000 Section 303-04D Fuel Charging and Controls - Turbocharger Description and Operation
- 2000 Section 303-04D Fuel Charging and Controls - Turbocharger Removal and Installation
- GTP38 Turbocharger Guide & Troubleshooting
- E99 vs. L99 - 03 Intake Spider Comparison
- Up-Pipe Install & DIY EBPV Delete
- Wastegate Actuator Adjustment (7-Turn Mod)
- T4 & SXE CSD Complete Installation Write Up
- T4 & SXE Turbo Parts List
- T4 & SXE Turbo Installation - Video
- Turbo Matrix - Compendium of Reviews of Different Turbos
HEUI Fuel Injectors
- Injector Troubleshooting
- Injector Break Out Box
- Injector Rebuild
- Injector Plunger & Barrel Parts
- Injector Buzz Test
- Injector Cup R&R
- Injector Torque Value Guide from Ford
- Injector Discussion
Fuel Related
- Low Fuel Pressure Diagnosis, by Les-F350towing
- Diesel Fuel Atomization
- Diesel Fuel Lubricity Additives Study
- KelVarnson's X-Ring QuadRing 4 Lobe O-Ring to replace bevel cut gasket on OEM Fuel Filter Lid
- Fuel Pressure The Easy Method
- Harpoon Mod
- Hutch Mod - SkySkiJason Method
- Hutch Mod - Guzzle Method
- Hutch Mod With Bed Off
- Hutch Mod Parts List
- Passenger Fuel Line Fix
Water Pump
- Water Pump Removal - 1 - Video
- Water Pump Removal - 2 - Video
- Water Pump (International) Install - 1
- Water Pump (International) Install - 2
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DRIVETRAIN
4R100 Automatic 4 Speed Transmission
- 4R100 Cooler Bypass Valve R&R 2000
- 4R100 Cooler Flow Test
- 4R100 Diagnosis & Testing
- 2000 Section 307-01 Automatic Transmission DIAGNOSIS AND TESTING
- 4R100 / E4OD Fluid Flush Procedure By Mark Kovalsky - Former Ford Automatic Transmission Calibration Engineer - Official FTE Article
- 4R100 Fluid Flush Photos
- 4R100 Fluid Change For TC Drain Plug Model
- 4R100 Gear Shift Linkage Adjustment
- 4R100 Gear Shift Selector Adjustment
- 4R100 Gear Shift Tube & Bushing R&R - 1
- 4R100 Gear Shift Tube & Bushing R&R - 2
- 4R100 Inline Filter Install
- 4R100 Overdrive Light/Wire Fix
- 4R100 Rebuild General Information - 1
- 4R100 Rebuild General Information - 2
- 4R100 Temperature Range
- Adding Oil to Water trans cooler, radiator, & lines for 1999-2000 models
- 6.0L vs. 7.3L Transmission Cooler Comparison
- Banks Transcommand Bypass
- 4R100 Sloppy Shift Lever - Video
- Replacing OEM 7.3L Oil to Air transmission cooler with a Dorman 26 row OTA cooler for a 6.0L
- Aftermarket Metal Shift Indicator Cable Bracket to Replace Broken OEM Plastic Bracket Holding Gear Selected Indicator Mechanism
- FTE Member BWST's 4R100 Transmission Rebuild At Home
- 4R100 Rebuild by Snowseeker
On April 25, 2021, three (3) links related to 4R100 listed below were found to be embedded with Viglink redirects, which are retained below for the record, but are not recommended to be clicked until an investigation as to how they became monetized and or redirected is complete. Once the links are determined to be safe, or are repaired, they will be reincorporated back into the 4R100 list immediately above, and these notations will be removed. Thanks for your understanding.
- 4R100 Rebuild & Technical Data (ATSG) DO NOT CLICK
- 4R100 Rebuild & Technical Data Update (ATSG) DO NOT CLICK
- 4R100 Shift Lever Harness Chafing DO NOT CLICK
ZF-6 Manual 6 Speed Stick Shift Transmission
- ZF6 Clutch Pedal Bushing Mod
- ZF6 Clutch & Related Parts Listing
- ZF6 Hydraulic Assembly Installation - Video
- ZF6 Removal Procedure
- ZF6 Disassembly Procedure
- ZF6 Pilot Bearing Alternatives
Transmission Swaps: Auto to Manual and vice versa
- ZF6 Swap into 2003 Super Duty by ESwift on FTE
- ZF6 Swap into a 1999.5 F-250 by Big_Stroker on Powerstroke.org
- ZF6 Swap into a 2001 F-250 by Mud-Nut on Powerstroke.org (Photos lost so no more pics)
- ZF6 Swap into an Excursion by Brodude07 on FTE
- ZF6 Swap into an Excursion by oharal on FTE
- ZF6 Swap into an Excursion by gavan on Pirate4x4
- ZF6 Swap into an Excursion by DozerDan on P4x4, who 9 yrs later swapped back to 4R100
NP-271 (Manual Shift) & NP-273 (Electronic Shift) 4x4 Transfer Case
- Transfer Case Fluid Change
- Converting OEM ESOF Rotary Switch to a 3 position Rocker switch, that fits within a bezel of similar rocker switches in a row
- 2WD Low In Reverse Mod - Video
- Section 308-07B Transfer Case Shift Lever Removal
- Section 308-07B Transfer Case Removal
- Section 308-07B Transfer Case Installation
Driveline Propshafts
- Driveline 101
- 2000 Section 205-01 Driveshaft Description and Operation
- Driveshaft Diagram
- Rebuilding A Double Cardan Joint: Tool List, Photos, & Videos
- Pinion Rotational Torque Ratings
- Slip Joint Maintenance
- Traction Bar Install (OUO) - Video
- Traction Bar Install (PMF)
- Traction Bar Install (Pro-Comp)
- U-Joint General Information
Hubs, Bearings, Wheel Ends
- 2WD Ball Joint Parts List
- 4x4 Needle Bearing Lube - 1
- 4x4 Needle Bearing Lube - 2
- 4x4 Electrical & Vacuum Schematics
- AutoLock Hub Disassembly & Lube
- ESOF & OEM AutoLock Hub 101
- ESOF AutoLock Hub Function Check
- ESOF AutoLock Hub Service - 1
- ESOF AutoLock Hub Service - 2 - Video
- ESOF Diagnosis 2002 MY
- ESOF Diagnosis 2000 MY Pt 1
- ESOF Diagnosis 2000 MY Pt 2
- ESOF Underhood Relay Location
- Grease Un-Serviceable Hub
- Mile Marker Hub Install
- Wheel Hub R&R
- Wheel Knuckle R&R
Front Drive Axle / Differential
- Dana 60 Front Differential Fluid Change
- Front Axle Swap: From 2WD Twin I Beam Coil Sprung to 4WD Straight Axle Leaf Sprung
Rear Drive Axle / Differential
- 1999 - 2003 Ford Sterling Final Drive Rebuild Procedure
- Pinion, Carrier & side Bearings in Sterling 10.5 Rear Differential R&R
- 08 Rear Differential Cover Install
- Rear Pinion Seal R&R
- Rear Axle Partial Parts List
- Rear Differential Fluid Change
- Rear Differential Cleaning
- Rear Hub Seal & E-Brake
- Rear Wheel Hub Bearing R&R - 1
- Rear Wheel Hub Bearing R&R - 2
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CHASSIS
Steering
- 4x4 Tie Rod Assembly Diagram
- Adjustable Track Bar
- Alignment DIY Method - Tie Rod Adjustment - Toe In
- Center The Steering Wheel
- Custom Power Steering Hose
- High Pressure Power Steering Hose
- Hydroboost Diagram
- Steering Gear Box Adjustment
- Steering Gear Resealing
- Power Steering Pump R&R - 1
- Power Steering Pump R&R - 2
- Steering Gear Adjustment
- Steering Gear R&R - 1
- Steering Gear R&R - 2
- Steering Gear R&R (V10)
- Steering Stabilizer - Single Bilstein - Monster4
- Steering Stabilizer - Single Bilstein - TIUSER
- Steering Wander - The Compilation
- Ball Joint R&R - 1
- Ball Joint R&R - 2
- Ball Joint R&R - 3 - Video
- How To Replace Clock Spring In Steering Wheel
Suspension
- Adjustable Track Bar
- AirLift Air Bag Install
- Bilstein 4600 Shock Install - Video
- Front Sway Bar Bushing R&R
- Front Sway Bar End Link Bushing R&R
- Leaf Spring R&R Tips
- Leaf Spring R&R - 1
- Leaf Spring R&R - 2
- Lift Shackle Install
- OE Rear Swaybar Part Numbers
- Shock Bushing R&R
- Spring Tech 101
- Airlift 88298 airbag install
- DIY Radius Arm Bushings 2WD F-350
Brakes
- 4 Wheel Anti Lock Brakes Diagnosis and Testing
- Bleeding Brakes
- Braided Stainless Steel Lines
- Brake Lines and Double Flares
- Cementite & Brake Rotors
- Changing Front Brake Pads & Rotors
- E-Brake Pedal Switch Fix
- E-Brake R&R
- E-Brake Shoe R&R With Hub On
- Parking Brake Upgrades (Including Mico Line Lock Options)
- Front Caliper Pin Maintenance
- Master Cylinder Bench Bleeding - Video
Wheels
Tires
FTE Leadership Emeritus
Joined: May 2014
Posts: 27,351
Likes: 5,945
From: Lake Hartwell, GA
HVAC System
- 2000 Section 412-00 Climate Control System - General Information Description and Operation
- Climate Control System Pinpoint Test 2002
- Climate Control System General Info & Specs
- Climate Control System General Info Diagnosis & Testing
- HVAC Vacuum Diagram
- HVAC Blower R&R
- HVAC Control Components (Pickup)
- HVAC Control Components (Excursion)
- 2000 HVAC Control Unit Wiring Diagram (Pickup)
- 2001 HVAC Function Selector Switch Wiring (Excursion, Gasoline)
- A/C Clutch Air Gap Adjustment
- A/C Clutch Air Gap Adjustment - Video
- A/C Evaporator Coil Cleaning
- A/C Evaporator Coil Cleaning - Video
- A/C (Ranger/Excursion Valve) Mod
- Wow - Real Air Conditioning
- Air Conditioning Mods: Consolidated Reference Materials
- R134a Temperature Pressure Chart
Interior
- 08-12 Front Seat Install
- Bucket To Bench Seat Install
- Change Interior Lighting From Green
- Clock spring Info
- Clock Spring R&R - 1
- Clock Spring R&R - 2
- Dash Bezel Swap to 05-07
- Digital Odometer Diagnostic Codes - Video
- DIY Upfitter Switches
- Door Cable Repair
- Door Actuator R&R - Video
- Door Actuator Repair
- F650 Dash Insert
- Front Door Window R&R
- Front Door Window Motor R&R
- Front Seat Cushion & Cover R&R
- Grab Handle Install
- Heater Core R&R
- In Dash Cup Holder Repair
- Instrument Panel & Console Removal & Installation
- Seat belt Replacement SuperCab - Video
- Seat Heater Install
- Steering Column & Wheel R&R
- Steering Wheel Swap
- Vinyl Headliner Tutorial
- Crew Cap Headliner Removal
- Window Switch Repair
Exterior
- 08+ Tail Light Mod
- 08+ Tow Mirror Connector
- 08+ Tow Mirror Upgrade - 1
- 08+ Tow Mirror Upgrade - 2
- Adding Tailgate Lock & Handle
- Aiming/Adjusting Headlight Beam
- AMP Research Running Boards
- Cab Clearance Lights
- Cowl R&R
- Front Passenger Wheel Well Plastic Liner Removal
- DIY Harley Davidson Headlight Housing
- Door Handle R&R
- Door Hinge & Fender R&R
- Door Lock Cylinder R&R
- Door Locks, Latches & Entry Systems (Module Controlled)
- Door Locks, Latches & Entry Systems (Non-Module Controlled)
- Headlight Housing Information By Year
- Lifting Cab Guide
- OEM Fog Light Install
- MOVE Rear Bumper fabrication and Front Iron Cross Bumper
- Ranch Hand Grille Guard Install - Video
- Roof Molding R&R
- Secret ZooDad Mod
- Swapping Paddle Mirrors To Tow Mirrors
- Tailgate Power Lock/Unlock
- Bend Reinforced and Illuminated Running Boards: Photo Essay Build by Big Horn 2
Misc Information & Modifications
- 7.3L Buying Guidelines
- Acronyms & Definitions
- AIS vs. 6637 Intake
- Did You Know?
- Engine Stand Mounting
- Failure Prevention Information
- Fastener Size Chart 30SEP21
- Fastener Size Chart 14DEC21
- Fastener Torque Spec By Type & Size
- Shop Manual - Helpful Tips For Understanding Shop Manuals and Wiring Diagrams
- Thread Insert
- Torque Spec By Part - 1
- Torque Spec By Part - 2
- Tow Hook Work Platform
- Accelerator Pedal Position adaptation for Echlin (Napa) sensors
- Y2K's Broken Rubber Begets Custom Bed Springs
Helpful Personal WebSites / Articles Created By Super Duty Owners
Helpful YouTube Creator Videos
Using Google To Search FTE (examples)
Last edited by Y2KW57; Dec 28, 2025 at 02:31 PM.
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Stewart_H
Excursion - King of SUVs
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1973dieselhighboy
1994.5 - 1997 7.3L Power Stroke Diesel
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