Not familiar with how those injectors are put together, but, is there room to open up that hole? Maybe making it bigger would get more heat in there, if they were designed to be heat shields?
The angles do look wierd to me, but had a low mile unmolested supercab in not to long ago that looked similar. There are ford manuals that list angles for all models if you can find one. Two piece driveshaft angles can be difficult to make work. Any signs of mods, trans swap, rear end swap/re...
I am not sure what in the diff could cause a vibration that could be felt, other than a bent pinion causing the yoke to run crooked.....
By your description of the problem, this sounds like an out of phase, or incorrect angles type vibration. Pictures would be nice if possible.
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
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