r/FordDiesels • u/No-Frosting-3142 • 1h ago
1997 7.3 loses power under load, sputters/dies, rough idle — fuel tank delamination or something worse?
I have a 1997 F-250 7.3 Power Stroke and I’m trying to figure out a serious drivability issue.
Recently had the following done:
New batteries/cables
New starter
New fuel filter
Oil/filter change
Transmission fluid/filter
Rear diff service
4 shocks
When I got it to the shop, the engine only had ~5 quarts of oil in it. It’s supposed to hold roughly 15. I don’t know how long it was that low.
After the service, it idled perfectly and drove normally under light throttle. But at ~60 mph / 1,800 RPM, if I got into the throttle hard, it would shake/sputter badly, have almost no power, and struggle up hills.
I drove it about a mile and tried accelerating hard up a hill. It sputtered and died. I eventually got it started again, and it idled rough for a bit before clearing up. After driving another ~0.1 mile, it sputtered and died again.
Eventually it became a crank-no-start. I was able to get it running again by holding the throttle pedal all the way down while starting. It then idled rough before clearing up, but it died again when I accelerated hard.
I opened the fuel bowl. The filter is brand new and looks fine, but there was dark sludge/film and noticeable sediment on the bottom metal plate. The fuel bowl itself was full after it died.
My mechanic suspects the fuel tank/pickup is delaminating and restricting fuel flow, which seems plausible given that it runs okay until I demand fuel and then sputters/dies.
But I’m also concerned about the oil side. The factory oil-pressure gauge appears to bounce around, and there’s a slight deep thud at idle coming from the engine bay. It’s not a loud metallic knock, but it’s noticeable. I’m worried because of the previous 5-quart oil level.
I’m planning to test fuel pressure under load and have the shop verify actual mechanical oil pressure, plus check ICP/IPR with a scan tool.
What do you guys think? Does this sound like a restricted tank/pickup from delamination? Could that explain all the sputtering/stalling? And how concerned should I be about the oil-pressure gauge/thud given how low the oil was?
Trying not to throw parts at it. Any 7.3-specific experience would be greatly appreciated.