1998 - 2003 7.3L Powerstroke

The 1998-2003 7.3L Powerstroke made significant upgrades from the original 1994-1997 OBS.

Adding an intercooler to cool the compressed air from the turbo increased the horsepower potential of the engine while also reducing exhaust gas temperatures (EGT). Ford also replaced the cam-driven mechanical pump with an electric lift pump to provide better fuel system performance. Another big addition was the upgraded Garrett turbocharger that now featured a wastegate. New higher flowing split-shot injectors were larger than the injectors used on previous generations. Another bonus was they were also significantly quieter.

A new 17° swash plate High Pressure Oil Pump (HPOP) was incorporated, up from 15°, to provide an increase in oil volume. These pumps can also better support performance modifications in the aftermarket. The 7.3L continued to utilize forged-steel connecting rods from 1999-2000 trucks, In 2001, they were replaced by weaker powdered-metal rods.

With each of these upgrades, horsepower and torque were continually bumped up over the years. Starting at an initial rating of 235 hp and 500 lb-ft of torque across the board and ending with a peak of 275 hp and 550 lb-ft of torque in the later manual transmission trucks.