I got my truck back yesterday from the repair shop. I sent it there to have everything checked, coolant changed and the brakes fixed (pulsated), 4" MagnaFlow exhaust and the Autometer gauges installed.

They found the truck in decent condition and a good candidate for mods. One of the mechanics has owned and modded a few 7.3s.

They found the driver's side exhaust manifold leaking. As
I got a great deal on the new manifold ($103.00) we replaced it rather than trying $30.00 gaskets from FelPro. The mechanics and I agreed that there was much less risk that the leak would reoccur if the manifold was replaced. FYI, the truck did not come with manifold gaskets nor does Ford sell them. Other members turned me on to the FelPros. Thanks.
When they removed the driver's side manifold, the up pipe fell out. The pipe had no flare, it was straight pipe. They flared it put it back in with a donut. Has anyone else had this problem?
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In went the 4” MagnaFlow SS exhaust. I knew I had an exhaust leak prior to the diagnoses but I only noticed it when the truck was cold. I figured the leak wasn’t that bad and my truck was just a slow slug. Well the truck is quieter with the 4” Magna flow than it was with the leaky exhaust manifold. I guess I attributed all the noise to a diesel engine and not the exhaust leak.
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In went the 6637 filter mod and Autometer gauges. I have to admit, the lighting on the Autometers could be tad brighter but I guess, they would be more distracting than they already are.

They found the passenger side ball joints were bad. The original owner replaced the driver’s side 3K ago. So in went Moog greaseable upper and lower ball joints.
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Front rotors were turned and rear rotors were replaced using PBR rotors. I chose PBRs because of their past reputation plus they were cheap.
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I am shocked that this truck passed Maryland State Inspection only 3K ago. The ball joints and right rear rotor were in bad enough condition that they should have failed 3K ago. The previous owner had the truck state inspected by PepBoys prior to putting it up for sale. From now on, I will have any vehicle I buy reinspected by an inspection facility of my choice on my dime to make sure everything is up to snuff.
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Coolant was changed from green to gold. I went gold as I could not find any reasonably priced concentrated ELC nearby and doubted the mechanics would be able to get anywhere near a 50-50 mix of antifreeze using prediluted as they wouldn’t open the block drains, etc.
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At WOT, I am running between 15-17 psi boost now. Is this right with the 6637 filter and 4” exhaust or should I be concerned about other leaks and some thing else?
Trans temps are around 125 degrees and EGT hovers around 700 – 800. I don’t tow and usually run an empty bed. Are these numbers normal?
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The truck runs and brakes good now. It is still a dog but definitely better than before. I wonder how much boost I was making with all those leaks.
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I was planning to order a DP Tuner when Jody comes back but have become concerned about what a tuner does to a stock trans. As I am not planning to tow anything and usually run with an empty bed, should I be concerned about shift kits and valve bodies? What if I add a snowplow and plow about 5 driveways when it snows?
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I would like to thank everyone for their input and the information found on this forum. You guys and gals are the reason the maintenance was done correctly and why the 6637 filter, gauges and exhaust are on the truck and why I have no money left in my bank account.

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Really everyone, thanks for all of the help and info..


Neil





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I don't know why my new paragraphs are gone - format changed from what I saw in preview post.

Sorry. I know it is difficult to read this way.

 

Congrats on all that!! Your boost is normal for a stock-tuned truck.

EGTs are about where they should be, if you mean when you get on it. Driving at highway speeds it should be 5-700, depending on hills, actual speed, wind, etc.

I would absolutely do the tranny first. You will get the most bang for you buck with the tuner if you do (and the tranny will last longer!).

 

What is the cheapest way of beefing up the tranny and what other aspects of the tranny will improve? I believe there are 162K on this trans so I don't want to risk it. I guess I should hold off on the tuner???????????

Can I get away without trans mods if I am light on the gas pedal?

Thanks..

Neil

 

Hi Neil,
I too had exaust leaks, and I also put 4" ss magnaflow turboback on the truck when I redid my up-pipes. I found the magnaflow seemed as quiet as stock even though it was straight threw. There was a extra pipe in my kit for the crew cab model, IIRC was 36"long and I cut it to 34" and used as a muffler delete pipe. The sound inside the cab isn't any louder as when I had the up-pipe leak. Well a little droneing at 1400-1600 rpm but not bad. I put a 4x5x12" ss tip on also. I'm getting old so I keep it under 2000 rpm and it sounds great, but if I WOT I hit 22lbs boost and the neighbours say it really barks (loud). So I will run straight pipe. I live in a rural area with no yearly inspections so I can get away with it.
Have fun with your truck it's the best truck i've owned
Colin