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10 Best 7.3 Powerstroke Upgrades for Peak Performance and Reliability

10 Best 7.3 Powerstroke Upgrades for Peak Performance and Reliability

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The 7.3 Powerstroke was first introduced in the market in 1994 and became an instant game-changer in the world of diesel trucks. This revolutionary diesel engine came with a new turbocharger and electronically controlled direct injection system. It had a displacement of 444 cubic inches (7.3 liters) and produced 210 hp and 425 lb-ft of torque. It was a powerful engine that offered reliability, durability, and high performance. 

The 7.3 Powerstroke underwent major modifications in 1998, and by 2003, it was producing 275 hp at 2800 rpm. It also had a torque of 505 lb-ft at 1600 rpm for automatic engines and 525 lb-ft at 1600 rpm for standard engines. However, production of the 7.3 Powerstroke was halted in 2003, paving the way for the 6.0L. 

Despite being out of production for nearly 21 years, the 7.3 Powerstroke is still a force to reckon with. It is regarded highly by many diesel truck enthusiasts, many of whom prefer it over other modern engines. The engine is still thriving in the market, and many truck lovers opt for it. If you are looking to buy a 7.3 Powerstroke Ford engine, keep reading this article to find out more about the necessary upgrades to optimize your truck's performance. 

Why is the Ford 7.3 Powerstroke a Prime Upgrade Candidate? 

The 7.3 Powerstroke is a prime candidate for upgrades because of the following reasons: 

First, it still has tremendous aftermarket support. Even long after its production, you can still find high-quality replacement parts and tuning solutions. This is majorly due to high demand. This facilitates performance upgrades for your engine, ensuring it lasts longer. 

Second, the 7.3 Powerstroke has a relatively low power and performance compared to modern engines. However, it can still be modified to enhance power. Another good thing is that truck lovers can choose the 7.3 Powerstroke over modern trucks, which are costly and some are unreliable. Upgrades for improved turbochargers, intercoolers, and fuel systems can increase horsepower and torque, improving the engine's overall performance. 

Additionally, the 7.3 Powerstroke is highly durable and reliable, guaranteeing longevity even after upgrades. 

What's more, this engine was designed in a simple way. This makes it easy to maintain, sometimes without even needing professional help. Its non-complex design makes it a go-to option for many truck lovers who prefer to care for their engines by themselves. 

Top 7.3 Powerstroke Upgrades 

Since its invention in 1994, the 7.3 Powerstroke has undergone many upgrades. However, as modern technology advances, these modifications continue to improve. These are some of the best 7.3 Powerstroke performance upgrades. 

Intercooler Upgrades 

Upgrading the 7.3 Powerstroke intercooler enhances performance and horsepower. It is even more effective when other parts, such as the turbo, undergo modification. To enhance engine performance, combine an intercooler boot kit with a high-flowing intercooler. When combined, they ensure optimal airflow, reliability, and durability. 

Choose high-quality intercoolers to avoid leaks and performance issues commonly associated with cheap ones. The best intercoolers are often larger than their replacement parts. It allows a greater amount of air to be cooled. 

Mammoth Performance Parts’ intercooler boot kits are some of the best you can find for your 7.3 Powerstroke. Our products are high quality, durable, and affordable. They are made of Silicone to increase air intake efficiency and resist cracks, splits, and UV rays. 

Performance Tuning 

One of the most critical 7.3 Powerstroke upgrades is the tuner modification. Tuners are the foundation of all modifications. They can boost the performance of every other upgrade and horsepower. You can upgrade your truck’s tuner to an electronic chip instead of the traditional one that is handheld. There are many tuner options available in the market. Some can even act as a performance booster and monitor. 

The tuner you choose will depend on other modifications on your truck and your desired engine power. 

Exhaust System Upgrade 

The initial 7.3 exhaust is prone to cracks and color changes. It is essential to upgrade it to a much larger one, especially one made with aluminum or steel. You can choose an exhaust pipe with at least 4 inches of diameter to reduce exhaust backpressure. It allows the free flow of gases, therefore improving turbo efficiency and reliability. A larger exhaust pipe also reduces EGT by up to 200 degrees. Ultimately boosting performance, power, and engine health. 

You can also upgrade exhaust brakes to slow down the truck, especially when it's towing. 

Upgraded Fuel System 

The fuel system is a diesel truck's major lifeblood. Upgrading it can increase horsepower and torque, ultimately enhancing the truck's performance. The 7.3 Powerstroke, especially the early ones, had traditional lift pumps. You can replace them with electric ones. They ensure adequate fuel supply and increased horsepower. 

Fuel injectors also need improvements. The 7.3 Powerstroke fuel injectors were less reliable. They could only perform best for about 350whp. Upgrading your truck’s injectors to stage 1 or 1.5 can go up to 400whp. Always pick injectors that align with your power needs and goals.

Performance Turbocharger 

Upgrading the 7.3 Powerstroke can boost power and torque. Stock turbos can go up to around 400whp. Conversely, upgraded turbos can perform even better. You can upgrade the turbocharger by replacing parts. However, it is advisable to replace it with a modern one. There are various turbo options available in the market. Go for high-quality turbos that guarantee performance and horsepower. 

Transmission Upgrades 

Upgrading the valve bodies in the 7.3 Powerstroke can increase engine power. Compared to diesel transmissions, the Stock 4R100 transmission can increase power for up to 350whp – 400whp. Manual transmissions such as ZF S5/S6 don’t need a lot of upgrading. 


Whether you are upgrading your truck's intercooler, tuners, fuel system, turbocharger, or transmitters, choosing the best parts is critical. High-quality parts from reputable distributors or sellers can guarantee high performance, reliability, and durability. Additionally, when upgrading, ensure your 7.3 Powerstroke can withstand modifications for a seamless driving experience. The above-mentioned 7.3 Powerstroke performance upgrades are the best modifications to start with.  

Mark M. Muhoro

Mark Muhoro is a car enthusiast and writer who loves everything about automobiles. With over 11 years of experience in the automotive industry, Mark has become an expert in how cars work and what makes them special. He writes clear and interesting articles about cars for magazines and websites, making valuable contributions to renowned platforms like Vroom Magazine, Internet Brands, and Contentmotive.

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