2003/1996 7.3 Swap - Ford Powerstroke Diesel Forum
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Old 06-12-2014, 11:22 AM
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2003/1996 7.3 Swap

I have a totaled (complete and running) 2003 F-250 with a 7.3 PS with 130,000 miles on it. I want to put that motor in my 1996 F-205 with a 7.3 PS that has 320,000 miles on it. They are both automatics. What all is involved in making the swap. I'm thinking on just using the doner motor for the long block. Am I on the right track or is it feasible to use the newer ECM, air intake system... I don't want to get into a bunch of custom fitting/fab work, combining wiring harnesses, adapters... What parts will I need to do the swap? Seems like it should be pretty a simple swap or is their something I don't know about yet?
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Old 06-12-2014, 11:50 AM
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The biggest problem is the fuel pump. 94-97 is a mechanical one driven off the cam in the valley of the engine. The 99-03 is a electric one.

Other than that, it is a direct bolt in using your accessories
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Old 06-12-2014, 01:09 PM
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Should be able to set the whole long block in. You will have to do e fuel and swap injectors (best just to buy new/remains because your 320k injectors are shot) and uvch's. Swap over your accessories and boom your done. I'm not sure if you can keep the turbo from the 03. It would be nice and then you could run an inner cooler.
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Old 06-12-2014, 02:54 PM
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Do I leave the e-fuel pump or injectors in from the 2003 or do I need a different set up? Do I have to time the e-fuel pump with the cam, tie into the CPS?
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Old 06-12-2014, 04:59 PM
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look into some of the e fuel swaps on here. most people delete the bowl and run the pump and filters under the truck. i can do that, but i see no reason you can't use the stock SD system.

your new motor will have PMR rods as opposed to forged rods, a 17* HPOP as opposed the a 15*, use the IC from the superduty though the pipes need some tweaks or use the OBS turbo set up, and you need to do something with the injectors
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Old 06-12-2014, 06:19 PM
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2003/1996 7.3 Swap

You can't run you 03 injectors with your 96 computer. 03 are split shots and your 96 is single shots. The tuning is different. That's why you have to use your 96 injectors in your 03 block or upgrade to some 160/0 or 160/30 single shot injectors. Your stock on your 96 are 120/0 and the 03 are 140/0. As for e-fuel I would keep the 03 fuel bowl and lines down to the frame and get your fuel pump from the 03 and hook it up after your selector valve. Use part of the wiring harness for the fuel pump to wire in your pump. You can also rob the fuel cut off switch also. It's behind the passenger side kick panel. There is a few threads on how to add a relay to your fuse box also. If you do it this way you will only have a few bucks into e fuel. The big set back is the cost of injectors. I found a full set of new full force injectors160/0 for a good price from a member here. He also caries powerstruck.

Last edited by sbluke55; 06-12-2014 at 06:38 PM.
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Old 06-12-2014, 06:22 PM
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Talk to hucory for injectors. He is a vender on here.
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Old 06-13-2014, 06:09 AM
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Thanks for all the help from everyone. This is all great info and pointed me in the direction I need to go.
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