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7.3 Powerstroke Engine Rebuild Cost – Worth Building a New One?  

It’s quite difficult to say the rebuilding cost of any engine because the cost depends on many factors such as type of rebuild, parts quality (aftermarket or OEM), parts availability, labor cost, etc. For some common problems in 7.3 Powerstroke engines like turbocharger leaks, faulty injector pressure regulators, and faulty EBPV valves, you might rebuild the 7.3 Powerstroke engine.

In general, for the complete rebuilding 7.3 Powerstroke, you can expect to pay between $9,000 – $15,000. The parts cost will be almost $7,500 – $12,000 and labor cost will be around $1,500 – $3,000.

Whatever it is, in this guide we’ve explored the 7.3 Powerstroke rebuilding cost and all the major parts that the engine requires.

At a Glance – Cost to Rebuild 7.3 Powerstroke

If you’re in a rush, go through this chart that should give you a good idea about how much you should budget for a 7.3 Powerstroke rebuild.

PartsApproximate Cost
Engine Block$1,000 – $2,000
Cylinder Heads$500 – $900 (OEM)
$1,500 – $3,000 (Aftermarket)
Turbocharger System$900 – $1,500
Fuel System$700 – $1,500
Exhaust System$500 – $1,000
Piston Set$200 – $500
Connecting Rod Set$200 – $700
Valve Train Set$200 – $500
EGR System$200 – $700
OthersAround $2,000

Related: Ford 7.3 Powerstroke Years to Avoid.

How Much does It Cost to Rebuild a 7.3 Powerstroke Engine? – Accessories With Price

It’s hard to give the exact cost as the cost will be dependent on many factors but the major ones are the quality of the parts, availability, brand, and the mechanic’s cost. However, here we’ve tried to give a range that will help you budget properly for the rebuild. 

1. Engine Block 

The engine block is the core of any engine rebuild and a big chunk of money goes into this. A 7.3 Powerstroke engine block can cost you anywhere between $500 – $1,500 depending on the condition, and availability.

And the total cost of the engine block including all the parts can be between $1,000 – $2,000. Engine block consists of many internal parts which are –

  • Cylinders – The engine block houses cylinders and the 7.3 Powerstroke comes with 8 cylinders.
  • Cylinder walls – These liners provide a wear-resistant and sturdy surface for the pistons so that they can move properly.
  • Crankshaft bearings – These bearings ensure support and smooth rotation for crankshafts.
  • Boreholes – Each cylinder comes with bore holes or sleeves which help to contain the combustion process on the cylinders.
  • Coolant Passage – Also known as oil galleries that deliver oil to different components of the engine.
  • Main Bearing Caps – They mainly secure the crankshaft in place.
  • Freeze plug – It’s also called core plugs, are used to seal the access holes, they can be removed if not necessary.
  • Camshaft Bearings – These bearings keep the camshaft aligned and help it rotate smoothly.
  • Lifter Bores – Engine blocks require these bores to house the tappets and also keep the tappets aligned. 
  • Oil Filter Mount – Most engine requires an oil filter mount which makes installing and removing filters easy.
  • Coolant & Oil Ports – Responsible for facilitating the oil and coolant flow to different components

Apart from these, there are a few others as well such as engine mounting points, dowel pins, etc. 

2. Cylinder Heads

The original cylinder can cost around $900. But if you go for aftermarket cylinder heads then you’re looking at $1,500 – $3,000. The aftermarket cylinder heads are expensive because the airflow, power, and reliability are better than the OEM. That being said, not every aftermarket parts are better than OEM ones. 

3. Turbocharger System 

An entire new turbocharger system can cost you anywhere between $900 – $1,500 if you’re buying a new. A used system can cost around $1,000. The turbocharger system includes the following components –

  • Exhaust manifold
  • Compressor housing
  • Turbine housing
  • Wastegate
  • Intercooler
  • Intercooler piping
  • Intake manifold 
  • Charge air cooler
  • Boost pressure sensor

4. Fuel System 

For a new fuel system, you should aim to pay between $700 – $1,500. Some aftermarket fuel systems can cost less, but sticking to the OEM would be best unless the aftermarket one is better. The fuel system includes the following components –

  • Fuel tank
  • Fuel pump
  • Fuel filter
  • Lines
  • Pressure regulator
  • Injector control module
  • Rails
  • Injectors
  • Pressure Sensor
  • Fuel Heater
  • Return line

5. Exhaust System 

Depending on the components and the brand, a new exhaust system can cost between $500 – $1,000. Old systems might come within $1,000 but if you’re not an expert then avoid buying used systems. 

6. Piston Set

In general, a high-quality piston set might cost you around $200- $500, used ones would be less than that. A piston set includes –

  • Piston pins
  • Piston rings
  • Pistons

7. Connecting Rod Set

A set of standard connecting rods can cost you around $200 – $700.Whereas, a set of performance connecting rods can require you to spend around $1,000. The set includes connecting rods and bearings. 

8. Valve Train 

For a new valve train, you might need to pay around $200 – $500 and used ones will come cheaper. However, if you’re not an expert then avoid buying used ones, you might end up buying something that’s not worth the money. The valve train includes the following components –

  • Valves
  • Valve springs
  • Seals
  • Keepers
  • Retainers

9. EGR System

An entirely new EGR system should cost you around $200 – $700, used ones will be less costly but you should avoid buying used EGR systems. The system comes with the following components –

  • EGR Valve
  • Cooler
  • Gaskets

Other Required Engine Components for 7.3 Powerstroke Diesel Engine Rebuild are:

  • Freeze plugs
  • Head bolts
  • Glow plugs
  • Main bearings
  • Timing belt 
  • tensioner

Video: 7.3 Powerstroke Engine Rebuilding Process

Labor Cost to Rebuild a 7.3 Powerstroke Engine

When you’ll pay a mechanic to rebuild the 7.3 engine, that will cost you a handsome amount. But it’s hard to say how much it would cost since the labor rate is different in various states. Plus, the price will depend on the mechanic’s expertise too.

However, to give you an idea we can say that in general, for a complete engine rebuild an average mechanic will charge around $1,500 – $3,000.

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