Things that are going through my mind on what to change or replace.
low pressure oil pump
Rear main seal
up-pipe gaskets and bolts
new exhaust bolts & manifold gaskets,manifold bolts,
Glow Plugs (Already done last winter)
New dipstick seal
Things I have copied or read about the removal
It can probably be done with shade-tree procedures, but I'd rent or buy the special lifting brackets the Ford techs use.
Here's the shorthand version of the procedures from the manual. All the details have been edited out to make it not so long, but the 63 steps are included. I'd use this list as a checklist, but I'd want a Ford workshop manual with all the details and illustrations handy if I were to even think about doing it.
SECTION 303-01C: Engine — 7.3L Diesel
Diesel Engine Lifting Bracket (D83T-6000-B) 303-D043
Fuel Line Tool (T90T-9550-S) 310-5039
Fuel/Oil/Turbo Protector Cap Set (T94T-9395-AH) 303-493
Heavy Duty Floor Crane 014-00071
Lifting Eye (D94T-6000-C) 303-D099
Fan Pulley Holding Wrench 303-478 (T94T-6312-AH)
Fan Clutch Nut Wrench 303-214 (T83T-6312-B)
Disconnect both battery ground cables.
Loosen the clamps and remove the air cleaner outlet tube.
Remove the air intake tube and adapter.
Lift the tube and adapter, disconnect the wastegate pressure hose, and remove the tube and adapter from the vehicle.
Remove the degas bottle.
Recover the refrigerant.
Remove the radiator grille, and the radiator grille opening panel.
Remove the three right side air deflector pushpins.
Remove the air charge cooler retainers.
Remove the radiator brackets and position the battery cable aside.
Remove the eight bolts and the radiator upper support.
Remove the radiator sight shield.
Disconnect the A/C condenser core inlet and outlet tubes.
Remove the A/C condenser.
Remove the inlet and outlet ducts from the charge air cooler.
Remove the charge air cooler.
Disconnect the upper radiator hose from the radiator.
Remove the bolts and position the fan shroud on the fan.
Disconnect the degas supply and lower radiator hoses from the radiator.
Remove the radiator.
Remove the fan shroud.
Using the special tools, remove the fan and the fan clutch from the water pump pulley.
Rotate the belt tensioner counterclockwise and remove the drive belt.
Disconnect the manifold absolute pressure (MAP) sensor hose from the turbocharger compressor manifold.
Remove the engine ground cable from the right side of the engine block.
Disconnect the A/C compressor electrical connector.
Disconnect the A/C manifold from the A/C compressor.
Disconnect the power steering hoses.
Disconnect the generator electrical connectors.
Remove the generator mounting bracket.
Remove the bolt from the left front of the engine block.
Disconnect the engine control sensor wiring electrical connector.
Disconnect the lower generator electrical connectors.
Disconnect the cable and the fusible link.
Disconnect the ground strap.
Disconnect the heater return hose.
Disconnect the heater supply hose.
Remove the turbocharger.
Using the fuel line tool, disconnect the fuel lines.
Remove the fuel line retaining bolt.
Remove the idler pulley.
Remove the nuts and position the glow plug and intake air heater relays aside.
Remove the bolts and the water outlet tube.
Install two engine lift adapters.
Install the special tool on the right side cylinder head.
Raise the vehicle.
Disconnect the starter motor electrical connectors.
Remove the three bolts and the starter.
Remove the torque converter housing cover.
Remove the torque converter-to-flexplate nuts.
Remove the oil filter.
Disconnect the block heater electrical connector.
Remove the engine mount nuts.
Remove the transmission-to-engine bolts.
Lower the vehicle.
Use a wood block and a suitable jack to support the transmission.
Remove the transmission oil level indicator tube.
Install the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket on the engine.
Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward out of the vehicle.
(Note that everything in front of the engine has been removed, so the lift doesn't have to raise the engine very much. But the 7.3L is about twice as heavy as a gasser, so a lightweight engine hoist won't do.)
Remove the engine lifting equipment from the engine.
Another Guy said
I did mine myself. I bought a short block. If I had to do it again I'd buy a complete engine. The job would have been much easier and faster. It is huge job not to be taken lightly. You have to remove the front end of the truck to get the engine out and it is BIG and HEAVY. Make sure you have a very heavy duty hoist. I had two differant stands, neither where heavy enough. We ended up leaving the new one in the crate and setting the old on jack stands on the floor to swap everything over. Swapping everything over was by the far the most time consuming task. I had about 24 hours in it myself and my buddy helping had about 14.
The more I dig into this the more I think I need to find a good diesel mechanic to work on my truck. This task is looking like a longer project than what I have time for.