Help Diagnosing 2002 7.3L problem(s) - Ford Powerstroke Diesel Forum
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Old 09-19-2011, 10:43 PM Fanatic

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Help Diagnosing 2002 7.3L problem(s)

2002 F350 7.3L, 6spd
10K Mod, exhaust, BHAF intake

I was driving today on a 200 mile trip. When I first took off, something didn't feel quite right, but I couldn't tell you why. The motor seemed to have more of a roar that normal at higher rpms. Kind of like a stuck fan clutch. It was close to 90 degrees today, so the roar is probably not out of the ordinary. Granted I don't drive the truck much, so it is tough to tell anymore.

So I am driving along no problems. About 80 miles into the trip, the truck seems to be drinking diesel. Gas gauge barely moved for the first 80 miles, then for about 20 miles it goes from Full to 3/4 tank. Definitely not normal. Normally I get about 175 miles before 3/4 tank. During that time I also notice the A/C not blowing as cold. Then suddenly the A/C starts blowing hot, as if the heater was on. I play with the A/C controls a bit and finally roll the windows down and turn the A/C off.

I had the A/C system recharged a few weeks ago and the tech mentioned if the A/C became intermittent I would need to adjust the air gap.

So now I am rolling with the windows down and notice a bit of a whine under light load. Sounds almost like a bad power steering pump whine, but only under very slight load. Any more load and the engine noise drowns it out.

I pulled over and checked the power steering pump and it was fine. Continued on to my destination playing with the gas pedal whenever I was passing a building, etc. to duplicate the noise. It isn't bad, but enough to bother me. I did just replace the clutch master cylinder a few weeks ago, so could it possibly be an issue there or maybe because of an issue with the master/slave the throwout bearing has gone bad?

Possibly the A/C compressor died and is making noise? I didn't notice any noise from it at idle though.

I am 200 miles from home with no tools. Any harm in driving it home then messing with it? Really just looking for ideas. Included the whole story in the hopes that might aid in armchair diagnosis.

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Old 09-27-2011, 05:35 PM
Powerstroke Junkie


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problem is you have a Gas pedal in a diesel truck, lol!!!

Sorry, just pickin. Hard to say without being there. First sounded like a boost leak, the AC and adjusting the air gap has nothing to do with the roar. I just adjusted my air gap last week, but it could be the reason why it isn't blowing cold.

You may want to post where you are and somebody in the area might be willing to take a look at it for you.
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Old 09-28-2011, 06:11 AM Fanatic

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Sorry the accelerator pedal....

My boost seemed to be right in the normal range. If I romped on it I could still get 17-20psi, so I don't think I have a boost leak.

I did adjust the air gap once I got back home and it seems to have resolved the A/C problem.

I am still on the stock clutch so it is possible it is starting to have issues.

The noise sounds like a bearing somewhere. Just have to wait for my hand to heal up so I can start digging into everything. I think I will throw it on jack stands and try to pinpoint the general area.

Thanks for the help.

In the Austin, TX area if anyone wants to help me diagnose.
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