Do you have a way to watch datastream?
Have seen the overboost code with programmer, and no check engine light. Everything to do with that chip clean and tight?
Any weirdness that isnt quickly diagnosed, I disconnect/remove any programmers or associated stuff, Pretty amazing how many times...
I agree, that something is causing the repeat failures, I work on these regularly, and have worked on that part so little that I dont even know any suggestions....
As far as throttle lag, I dont know what to call it, but these early 7.3 powerstrokes for sure do have some throttle weirdness...
Sounds like you have had a bad run of parts. Try an oem one from a junk yard? That system is relatively trouble free, have replaced far more idi throttle cables than pedal assy, or tps sensors in the 7.3 powerstroke.
I used a couple sets back when they where available. I dont remember how much, but towing mpg was much better with the g codes vs bb.
If you dont use the g codes and want to sell them, I would be interested in them.
Does it sound like it is cranking normally, or does it sound uneven, with loud air noises coming out of the intake.
I would bet you are just seeing blowby vapor from the cdr valve.
Have any pictures of how it is broken?
Know a few guys that replaced broken 60s in the old fords with 10.25s. Didnt sound like they ran into anything difficult.
Are you positive you put the same size wheel cylinders back in it? I recently did the same job on my truck, was in a hurry and did not compare wheel cyinders. Pedal is very slightly different now, and rear brakes are very aggressive. I sm betting that this is what changed with mine
I would bet something knocked that electrode off. At this point I would be pulling the engine. Maybe it can be saved, but buy your description I would bet not.
If you have a way to get the cab off, it is a very easy engine r and r.
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