7.3 Powerstroke Upgrades
January 18, 2022

7.3 Powerstroke Upgrades

Written By: ProSource Diesel

When it comes to upgrading your 7.3 Powerstroke with aftermarket diesel parts, it’s important to remember that this is a truck where most models are over 20 years old. Some 7.3 Powerstroke upgrades are necessary simply to keep your truck on the road.

Nevertheless, the 7.3 Powerstroke is regarded by enthusiasts as one of the best Powerstroke engines ever made. It didn’t have the head gasket issues that plagued the 6.0 Powerstroke, and it also didn’t have any emissions problems that the 6.4 and 6.7 Powerstroke engines had. This makes the 7.3 Powerstroke incredibly reliable and ripe for upgrades.

When it comes to diesel engines, it’s all about airflow. Creating greater airflow unlocks the potential for more horsepower and torque. Let’s take a look at some recommended 7.3 Powerstroke performance upgrades to get the most out of your engine.

Intake Upgrades

There are two main ways to upgrade the intake system on your 7.3 Powerstroke. One way is to install a cold air intake. Cold air intakes are a relatively inexpensive way to increase airflow into the engine. This helps turbo efficiency and can lead to gains of up to 15 horsepower. The other method for upgrading your intake system is to get an intercooler upgrade kit like the Banks intercooler upgrade kit for the 7.3 Powerstroke. The Banks kit includes a larger, higher-efficiency, all-aluminum end kit, which is generally far superior to the stock plastic versions. An intercooler upgrade will also help airflow through your engine and provide increases in both power and fuel economy.

7.3 Powerstroke Upgrades

Banks intercooler upgrade kit for the 7.3 Powerstroke

Turbocharger Upgrades

There are a lot of options when it comes to turbo upgrades for the 7.3 Powerstroke. Newer aftermarket turbo upgrade kits have the potential for large horsepower gains. However, it’s important not to take things too far or your engine and transmission might not withstand it. If you’re buying a used Ford truck with the 7.3 Powerstroke, you may need to replace the turbo anyway. The Spoologic turbo line is a great choice for replacing your turbo. Another option is a turbo rebuild kit to bring your turbo back to like-new status.

Symptoms of turbo failure include loss of power, increased oil consumption, excessive black or gray exhaust smoke, and a whining sound from the turbo.

7.3 Powerstroke Upgrades

SPOOLOGIC GTP38R Ceramic Ball Bearing Turbocharger Red For 99.5-03 7.3L Powerstroke

Head Studs

Aftermarket head studs are an extremely important upgrade for your 7.3 Powerstroke engine if you’re aiming for considerable horsepower gains. Upgraded head studs, like the TrackTech Head Stud Kit, are essential for durability, and they outperform OEM head bolts. The TrackTech kit features some of the highest tensile strength available at 240,000 PSI. If you’re going for high-performance, then head stud upgrades should be on your list.

7.3 Powerstroke Upgrades

TrackTech Head Stud Kit For 1994-2003 Ford Powerstroke 7.3L

Exhaust Mods

Upgrading your 7.3 Powerstroke exhaust is also a good idea. Stick with a four-inch exhaust, but otherwise, you have a range of options from steel to aluminum. If you have a used 7.3 Powerstroke, it’s possible that you might experience symptoms that point to cracked or leaking collector flanges on the up pipes. Replacing both the 7.3 up pipes and down pipe is a good idea for an older 7.3 Powerstroke. Additionally, you can install an exhaust brake to slow down the engine in downhill situations when towing.

7.3 Powerstroke Upgrades

BD Diesel Remote Mount Exhaust Brake For 94-97 7.3L Ford Powerstroke


You won’t get the most out of your 7.3 performance upgrades without a quality tuner. A tuner like the Banks Power AutoMind 2 can increase horsepower by up to 112 and torque by up to 205 pound-feet. The Banks Power AutoMind 2 tuner works as both a performance tuning device and a diagnostic scanner. You can adjust or remove engine revs and the top speed limiter as well as calibrate your speedometer based on your tire size and gear ratio.

There are many options for performance tuners on the aftermarket. Another one to consider is the Superchips 1050 Dashpaq In-Cab Tuner. This tuner works as both a performance tuner and a monitor. It can increase horsepower in your 7.3 Powerstroke by 100 and torque by 200 pound-feet.

A tuner is the final stage upgrade that takes advantage of the previous upgrades on this list to provide additional horsepower and torque. The bolt-on upgrades prepare your engine to be tuned for better performance and durability.

7.3 Powerstroke Upgrades

Banks Power AutoMind 2 For 1999-2019 7.3L 6.7L 6.4L 6.0L Powerstroke and the Superchips Dashpaq In-Cab Tuner For 94-19 Powerstroke


At first, it might seem challenging to figure out which 7.3 Powerstroke performance parts will help you get the most from your truck. You can use this list as a starting point to make it easier to choose the right upgrades for your truck and your specific needs. ProSource Diesel proudly stocks a wide selection of quality diesel truck parts, including 7.3 Powerstroke parts for your Ford truck. ProSource is where the diesel repair shops shop for diesel parts.

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