The 2000 F-350 with the 7.3L Power Stroke is one of the most bulletproof diesel platforms Ford ever built, but it's not without issues. Most problems center around injectors, high-pressure oil systems, and transmission cooling — all manageable if you catch them early.
Injector O-Ring and Cup Failure
Common · medium severityTypical onset: 150,000-250,000 mi
Symptoms: hard starting when cold, white smoke on startup, rough idle that smooths out when warm, oil in the valley or fuel dilution in oil
Fix: Replace all eight injector O-rings and copper sealing washers (cups). Requires valve cover removal, injector extraction, and careful cleaning of injector bores. 8-12 hours labor depending on technician experience and seized injectors.
Estimated cost: $1,800-3,200
High-Pressure Oil Pump (HPOP) and IPR Valve Failure
Occasional · high severityTypical onset: 180,000-300,000 mi
Symptoms: extended cranking before start, loss of power under load, ICP (injection control pressure) codes, truck dies and won't restart until cooled down, surging at idle
Fix: HPOP itself can fail (seals, rotors) or the Injection Pressure Regulator (IPR) valve sticks. IPR alone is 2-3 hours; full HPOP replacement requires removing turbo, intake, and valley components — 10-14 hours. Many techs do injectors at same time since you're already there.
Estimated cost: $800-1,200 for IPR; $2,500-4,000 for HPOP
Transmission Oil Cooler Line Failure (E4OD/4R100)
Common · high severityTypical onset: 120,000-200,000 mi
Symptoms: transmission fluid leaking near radiator, transmission running hot, harsh or delayed shifts, milky transmission fluid (coolant contamination), catastrophic transmission failure if coolant mixes
Fix: Factory cooler lines rust through or the internal radiator cooler fails, allowing coolant and ATF to mix. Requires new cooler lines, often external auxiliary cooler upgrade, complete fluid flush. If coolant got into trans, full rebuild needed. Line replacement alone: 3-5 hours. With trans flush and external cooler: add 2 hours.
Estimated cost: $600-1,200 for lines and cooler; $2,500-4,500 if transmission contaminated
CMP (Camshaft Position Sensor) Failure
Common · high severityTypical onset: 80,000-180,000 mi
Symptoms: sudden stalling with no restart, cranks but won't fire, no tach reading while cranking, P0340 or P0341 codes
Fix: The CMP sensor in the front cover fails, usually without warning. Truck dies instantly and won't restart. Sensor itself is cheap but requires removing fan shroud, fan, and working in tight space. Critical to check CMP wiring harness connector for oil intrusion. 1.5-2.5 hours labor.
Estimated cost: $250-450
Turbo Up-Pipe and Pedestal Leaks
Occasional · medium severityTypical onset: 150,000-250,000 mi
Symptoms: exhaust leak sound under hood when accelerating, loss of boost pressure, black smoke under load, visible soot around turbo inlet, check engine light with underboost codes
Fix: The up-pipes (exhaust manifolds to turbo) crack at welds or the pedestal O-ring fails. Requires removing turbo, fabricating or replacing up-pipes, new pedestal seal. Aftermarket bellowed up-pipes prevent recurrence. 6-10 hours depending on stud condition and parts availability.
Estimated cost: $800-1,800
Glow Plug Relay and Glow Plug Failure
Common · low severityTypical onset: 100,000-200,000 mi
Symptoms: hard starting in cold weather, extended cranking below 40°F, white smoke on cold start, glow plug light flashing or staying on, one or more glow plugs showing infinite resistance
Fix: The glow plug relay (under hood, driver side) fails or individual glow plugs burn out. Relay is 0.5 hours; individual glow plugs 0.3-0.5 hours each if they come out clean. Seized glow plugs can snap off, requiring head removal — budget 15+ hours if that happens. Always check relay first before condemning plugs.
Estimated cost: $150-300 for relay; $400-800 for all eight glow plugs if accessible
Fuel Bowl Heater and Drain Valve Leaks
Occasional · low severityTypical onset: any mileage
Symptoms: diesel fuel puddling under truck on passenger side, fuel smell in cab, fuel dripping from fuel filter housing, hard starting after sitting overnight
Fix: The fuel filter bowl has a drain valve at the bottom and an electric heater element that both leak over time. Drain valve O-ring is cheap and quick (0.5 hours). Heater element requires new gasket and careful torque (1 hour). Many techs delete the heater entirely and plug the hole.
Estimated cost: $100-250
Exhaust Back Pressure Valve (EBPV) Sticking
Occasional · low severityTypical onset: 100,000-200,000 mi
Symptoms: loss of power at highway speed, excessive black smoke under load, high EGTs (exhaust gas temps), turbo whistle changes pitch, P0470 codes or actuator codes
Fix: The EBPV (exhaust brake) in the downpipe can stick closed, choking the engine. Many owners simply remove the internal butterfly plate and leave the housing, or delete entirely. Removal/modification: 2-3 hours. Replacement if keeping stock: 3-4 hours.
Estimated cost: $200-400 for delete; $600-900 for OEM replacement
Absolutely buy one if maintained — the 7.3L Power Stroke is legendary for longevity, parts are cheap, and every diesel tech knows them inside-out.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.