Power Stroke
Turbo
Rebuild

The 7.3L Power Stroke received three distinct turbocharger configurations across its production run. The 1994-1999 early trucks used the Garrett TP38 -- a fixed geometry single turbo with no intercooler on the earliest examples. Ford added an intercooler and wastegate to the TP38 around 1999 but the housings remained the same 4-bolt configuration. The TP38 is identifiable by its 4-bolt compressor housing.

The 1999.5-2003 trucks received the upgraded GTP38, identifiable by its 5-bolt compressor housing, larger wastegate, and updated compressor wheel. Power Stroke badges moved from the fenders to the doors at the same production cutoff. The simplest way to identify early vs. late: fender badges mean TP38, door badges mean GTP38. Production cutoff date is December 13, 1998.

The EBPV (Exhaust Back Pressure Valve) variant exists on some trucks. EBPV-equipped turbos have a valve in the exhaust housing that restricts exhaust flow during warm-up. Many owners delete the EBPV when rebuilding -- confirm which configuration your truck uses before ordering parts.

Garrett Part Numbers -- GTP38

Ford / Navistar Part Numbers

The 6.0L Power Stroke uses the Garrett GT3782VA variable geometry turbocharger -- one of the most frequently rebuilt diesel turbos in North America. The VGT vane system allows the turbo to spool quickly at low RPM and continue building boost through the full RPM range. The downside is that the variable geometry mechanism is sensitive to the coolant and oil contamination issues the 6.0L is infamous for.

There are three distinct part numbers for the 6.0L GT3782VA, determined by engine serial number and build date. Using the wrong part is a common and expensive mistake:

• 725390-5006S -- 2003 only, build date 9/28/03 and earlier, engine serial below 6,000,000
• 743250-5024S -- 2004-2005 early, build date 9/29/03-11/3/04, engine serial 6,155,637-6,344,932
• 743250-5025S -- 2005.5-2007, build date 11/4/04 and later, engine serial 6,344,943 and above

The updated CHRA on later GT3782VA units includes a machined recess in the center housing that allows moisture to drain away from the unison ring and vane mechanism -- the primary cause of VGT corrosion and sticking on high-mileage trucks.

Ford / Navistar Part Numbers

The 6.4L Power Stroke uses the BorgWarner V2S sequential compound twin turbo system -- two turbos working in a staged arrangement. The small high-pressure (HP) turbo spools quickly at low RPM for fast response and hands off to the large low-pressure (LP) turbo at higher engine speeds for peak flow. Both turbos have variable geometry vanes electronically controlled in sequence.

The high-pressure turbo is BorgWarner 479515 (CHRA only: 479519). The low-pressure turbo is BorgWarner 479523 (CHRA only: 479526). The matched actuator calibration between the two is critical -- the V2S system requires the vane response on both turbos to be synchronized. This is why the actuator must also be replaced or recalibrated when either turbo is rebuilt.

Both turbos must be rebuilt together. Running a fresh HP turbo against a worn LP turbo creates boost delivery that the PCM cannot properly manage, causing boost spikes and uneven VGT operation that shortens the life of the new unit immediately.

BorgWarner Part Numbers

The 6.7L Scorpion Power Stroke uses the Garrett SST3266V DualBoost -- a single VGT turbo with a double-sided compressor wheel. The DualBoost compressor draws air from both sides of the wheel simultaneously, increasing airflow capacity without increasing wheel diameter. Combined with ball bearings and variable geometry, it delivers response and output that previously required a compound twin turbo setup.

There are multiple part number variants depending on model year and chassis configuration. Pickup and Cab and Chassis applications use different units and are not interchangeable. The 2015-2016 pickup variant (892147-5001S) requires an updated coolant supply line not used on earlier trucks -- a detail that catches many shops off guard on post-2014 rebuilds.

• 851824-5001S / BC3Z-6K682-A/C -- 2011-2014 Pickup (F-250/350/450), wide frame
• 854572-5001S / BC3Z-6K682-B -- 2011-2016 Cab and Chassis (F-450/550), narrow frame
• 892147-5001S -- 2015-2016 Pickup, requires updated coolant line

The 6.7L ball bearing unit is water-cooled in addition to oil-cooled. The coolant feed and return lines must be inspected and replaced if deteriorated during any rebuild. A blocked coolant passage on a ball bearing turbo causes rapid thermal damage to the cartridge after hot shutdown.

Garrett / Ford Part Numbers