02 7.3 boost issues - Ford Powerstroke Diesel Forum
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Old 01-29-2014, 11:28 AM
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02 7.3 boost issues

I know that this has been kicked to death in other threads, but I am struggling with finding a solution.

A little history:
Last year I had no boost at all from a broken intercooler can, I have since replaced the intercooler with a 6.0 and all new boots. The truck generally runs about 30 PSI on the extreme setting. I have only put about 500 miles on the truck since I did the swap a year ago.

I had the truck out a couple weeks ago and it ran great, 30 psi. I jumped in it the other day to pull a friend from the ditch and I couldn't get over 10 psi out of her.

Figuring that it was an intercooler boot issue, I made a pressure test cap and pressurized the system to 15 PSI. Now mind you, i still have the CCV in factory condition (no mods or delete).

I can hear some air leaking, but cannot seem to find any leaks at all. Seems to sound like it is coming from the passenger side of the engine.

Correct me if I'm wrong, but I assume that it would take a pretty big and noticeable leak to only build up 10 PSI....

I am starting to wonder if the turbo is just not building enough boost when the truck is running...??

Im starting to run out of ideas. Any help would be great

Truck Info:
2002 7.3 with 130,000 miles
Bully dog tripple dog tuner (on extreme all the time)
Bully dog outlook info center (typically see a peak of 31PSI)
4" turbo back exhaust
S and B cold air intake
6.0 intercooler upgrade
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Old 01-29-2014, 12:01 PM
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Hmm impressive that you're getting 30lbs of boost. Try unplugging the waste gate solenoid and see if that helps. Its the 2 wire plug on the aluminum intake pipes.


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Old 01-29-2014, 12:40 PM
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Ill give that a shot when I get out of work. Im not certain that Im getting 30psi, but thats what the outlook says. An auto meter gauge may say different (less) .....
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