7.3 IDI Turbo -Navistar International's ugly secret?

[MendoJim94]

Hi All. I posted a "hello" post in the newbie section today. Anyway, what's the deal with our engine? From what I could find so far, the 7.3 IDI Turbo was the first factory built 444 turbo engine made for the Ford F series trucks. Correct me if I am wrong, but from what I have found, prior to the TD444 (I hope that is the correct designation for this engine) if you bought this truck new from Ford, you could have a Turbo kit installed at the dealer level.
Sometime in mid to late 1993 International began building this engine with a turbo option from the factory. I guess the run was mid to late 1993 - mid-year 1994. The truck my wife and I bought was a factory order from Ford.
We placed the order a week or so before Thanksgiving 1994, and took deliver the first week of January 1994. It had about 6 miles on it. This was a full-boat optioned truck. Super cab, XLT trim level, High back recliners with the fold down center console, cruise control, "premium radio package" haha..AM/FM cassette, with 4 speakers. (Side note) from the get go, anytime you were on an AM station, a brake application gives you an ugly buzzing from the radio..nice. It's equipped with the E4OD trans, 4X4 with manual transfer case and manual locking hubs. Current mileage: 98,000. It looks almost new. So, I just went round and round with a transmission problem. Since we have owned the truck, we have been religious on all service...especially the transmission. In October on a trip to Death Valley, the trans light began flashing. At the end of a long, expensive road, I now have lots of new parts, including a fresh rebuilt PCM with the most current software, and my original PCM, fully overhauled, checked and ready to use as a good spare.
I found out the hard way that Ford stopped carrying the PCM for my 1994
in 2004. I guess by Fords standards, this truck was supposed to be a bunch of Honda's and Toyota's by now...NOT! Why else not stock a critical part like a PCM?
So, how many TD444's are there in the world? Are most mated to the E4OD, or to 5 speeds? Are we like a small minority because we don't have the all-mighty Powerstroke or what? As of a few days ago, my trans has been fully rebuilt and has some new bullet proof, upgraded parts, let alone a shift kit and torque converter. I had the transfer case split and found it had some minor damage to the case from the plate that holds the transferr case pump. It was still minor enough that JB weld took care of it, and it's been beefed up. I was told that this is pretty common to this transfer case.
So, until this transmission problem, my truck was bullet proof. As of now, it's a bit of a hard-starter, It used to fire up on first crank. Now, it's second crank and hold a bit. I still love this truck..so anyone out there?

Jim

[asauer]

No, these trucks are not extremely rare, but of course, they're not as popular or well-known as the powerstrokes.
In my opinion, you bought a better, more reliable truck because of its simplicity compared to the newer vehicles. Since you bought it new and take care of it, I'm sure it's still a really nice truck. I'd keep onto it forever.
But about the E4ODs, they are most certainley not rare either. I'd say the great majority of these trucks came with automatics. I can't help you much with the PCM and whatnot, but I don't see why it would be a difficult part to find. I still have the computer in my truck- never took it out after my 5-speed swap. If you really need one I could pull it out for you.
About the hard starts- how long does your "Wait to Start" light stay lit when the truck has sat overnight? I believe the specs are from 8-12 seconds being average, depending on the ambient air temperature, of course. If your glow plugs are in poor shape you will get this hard start condition. If the wait to start light is staying on for the normal length of time, and your truck only becomes hard to start after sitting a long time, I would take a look at the fuel return lines next. They will be on top of the engine around the injectors- there are plastic caps surrounding the injector with hoses connecting all the injectors together and terminating at the back of the engine on a distribution block that has a line running back to the fuel tank to return the fuel. If there is fuel seeping around the plastic caps, it means the o-rings have dried out and are letting air get into the system and therefore the fuel will 'bleed down' overnight back to the tank. When you start it the next day, you have to draw the fuel all the way back up, causing obvious problems.

[Bill1013]

So what is the question after that long oratory? HARD START?, prolly glow plugs, or air in the system. Auto MFG. are only required to supply OEM parts for 10 years, after that most likely someone will supply the parts if there is a demand for them.

[cdnsarguy]

the trans light began flashing

Probably the Fuel injection Pump lever sensor (FIPL) probably just needed resetting or a new one maybe..... $50

A long expensive road has now hopefully come to an end now your here.... I'm sure all the info re ""'I was told that this is pretty common to this transfer case"" came from the guy who was nice enough to rape you while fixing it.......

I too have been at the end of a road with a Harvey handyman garage the only thing to help you...... but your here now and we pride ourselves in helping people FOR FREE..... you do have to put a little effort in to help us though..... give us all the info and fact re a problem and members will do their darnedest to help YOU fix it or lead you to a descent shop/supplier.

[typefour]

These transfer cases are not problematic, what he should have said was the thing that fails is the pump bracket then there is no lube oil to the shafts and it eats the fork end off then wont stay in gear. I know this firsthand. I would highly recommend synthetic oil in the transfer.
As a matter of fact if you put 90 wt in the transfer it wont make it 20 miles before it rips the pump off the bracket. A local lube shop had a guy years ago that was changing the oil out to gear lube because "all transfer cases were made that way." They bought 5 before they fired him.