I have a 2002 Excursion with the 7.3 td in it I have 160,000 miles on it and it is all stock I have noticed in the last 6 to 8 weeks that it has developed something simular to an exhaust leak. I have taken it to a muffler shop and they are saying that all is tight I have taken apart the tube in the front and replaced it. I have a slight oil leak coming from the bottom of the hpop so slight that it only creates a slight puddle in the valley in between oil changes I have been told that I have the new inj. in cylinder 8, Question is if the fuel pump is not producing the right psi for the injectors will that cause a ticking noise. I wanted to ask before buying a new one and installing it. I do regular oils changes and fuel filter changes every 3500 to 4500 miles ever since it was new I am using rotella 5w 30 synthetic. I have also been told to change the oil to another brand and that will help quiet it down. Performance of the truck is great but seems to bog down right at takeoff from a dead stop. I average around 18.5 to 20.5 mpg depending on the road and driving habits. If I step on the gas harder the ticking goes away but when i let off of it it comes back. Please try to point me in the right direction with this.
Thanks in advance

 

It's common to hear ticking and knocking noises from these engines. As long as everything is buttoned up tight and you are still getting good fuel mileage, then your truck is running fine.

The reason for the extra noise is Ford's approach to the fuel system. The fuel tank has several design flaws in the pickup assembly, fuel line fittings, as well as flaws with the fuel rails. Ford's "band-aid" was to throw in a long lead ("LL") injector into the #8 spot to try and cure excessive knock, and to try additional sound deadening.

The in-tank fuel mods, also known as the "Hutch" mod, cures a problem of drawing in air with the fuel inside the tank. Also modifying the lines between the tank and fuel pump by removing the quick-disconnect fittings keeps air out of the fuel lines. As for the fuel rails, there are two options: one is a "Cackle Cure Kit" which eliminates the dead-head fuel rail setup, and the other is the "Regulated Return" which does the same thing but also includes a fuel pressure regulator. Many people have done these modifications in order to quiet down the PSD. Search around for the Hutch Mod, In-tank and pre-pump mods, Cackle Cure Kit, and Regulated return. There are many vendors and different approaches for each of these modifications, but all of them work well.

 

I agree with Curtis and the fuel system.. Mine ticks but what really helps is to use some biodiesel, about 2 or 3 gallons per tank full..It will make the ticking (which I believe is #8 injector, go away) ...I have made most of the mods, (see my signature) and still get a tick without the bio.. Our Safeway store is now selling 10% biosel..