ebay....1 left
https://www.ebay.com/itm/Motorcraft-DY967-Throttle-Position-Sensor/173824562386?hash=item2878c054d2:g:938AAOxy79JRf2zD
what makes you think something is wrong with your TPS? They rarely fail and most times it's misdiagnosed as the TPS when the culprit is the IVS
stock boost is around 15psi, chip only can get you into the 20s so a 30psi gauge is adequate
fuel pressure should be between 65-75 psi with stock fueling, chip will make no difference in fuel pressure.
Note that you need to tap into the fuel bowl to get a reading, it's more involved than a...
How much refrigerant in the system?
Try jumping the low and hi pressure cutout switches momentarily to see if you can get the clutch to engage with the a/c turned on.
I can take up to 10-20 miles of driving to get all of the air out of the HPO system.
Also could the coolant system have an air pocket that isn't allowing it to hold pressure? I would drive it at operating temp for a while until trying to check the coolant system again.
What is the condition of the oil pan on the donor engine? If it is solid I would leave it as is, maybe paint it with POR15 for added assurance?
EDIT
saw you already replaced the oil pan and buggered the up pipes.
I like the phrase "fix until broke".
At what point does "preventative...
doesn't seem like a big deal since you'll have the transmission harness from the donor truck
actually when you want to go to an auto you might get a good enough price for your manual transmission PSD to roll into an automatic tranny truck (maybe even newer....SD?)
I'd check the oil pan to make sure it's not rotting away.
Whatever transmission works best for you, go with it.
You could probably sell the zf5 swap stuff for more than you paid for the entire truck.
Unless you tow heavy the E4OD is "good enough" behind a 7.3
what source did you get the stainless cups? I'd only go OEM for cups if it was my truck.
Another long shot is try tightening the injector hold bolt...I believe it is 10 ft/lbs but I've gone as tight as I can get with a 1/4 drive socket.
Loose injectors are more common than you would think...
I'd still be on injector o-rings or cups. The problem is showing itself intermitently depending on how that o-ring or cup fails during the cold/hot cycle of driving the truck.
probably poor fuel or water in fuel from the fill-up. I'd keep the reciept handy in case of any further damage but a 7.3 PSD can most of the time handle poor fuel unlike the newer PSDs
head gasket on a 7.3 PSD is extremely rare, even when modded well above stock.
could be a head gasket failure that only shows itself under boost...like driving home for 4 hours straight on the highway. You could try driving it like grandpa around town and see if it looses coolant.
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