99-03 Ford 7.3 Powerstroke Dorman
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- Опубликовано: 21 окт 2024
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99-03 Ford 7.3 Powerstroke Dorman #DOR 615-201 valve cover gasket failure.
Ron Williams
Mobile Fix Automotive
26793 Madison Ave Suite 100
Murrieta, Ca. 92562
951-579-7146
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Information you need to know about installing the Dorman valve cover gasket on a 7.3 powerstroke diesel engine part number d o r 615 - 201
Mine failed in a month, wire covering split.. very handy.. Dorman is pure garbage. Thanks for the Video Ron!
So I was most of the way done with my injector replacement had covers back on and torqued, called it a day went on yt and this video popped up....next day took covers back off (I really didn't want to) and sure enough pinched the wires exactly where you pointed out the problem....THE HELL WITH DORMAN!!! THANK U SO MUCH FOR MAKING THIS VID
Hey Ron, Thanks for the video. I've been a mechanic the 13 years , never worked on a 7.3 before, now I have one in front of me. So very nice to be forewarned .
Wish I could post a picture I just pulled my drivers side valve cover because I’ve been having glow plug issues and I’m thinking possible even injector issues. As soon as I lifted my valve cover sure enough a smashed doreman valve cover gasket!! Installed bu a very reputable shop in my area! Thanks ron been using your videos trying to get my truck running better!
Great video. This has been hashed out in the Ford forums over the last few years. I pinched mine on install as well 2 years ago, and it grounded out 2 of the glow plugs to the valve cover. Glad you could make a video for everyone. My Dorman replacements are going on 100k with no internal failures like the OEM harness had. I clipped off just the two zip ties closest to the plug.
You removed the zip ties closest to the plug or am I not understanding what you are saying?
@@jacoe33333 Yes. The centered input plug being the reference, go to each side of it and remove those two tiny zip ties. This will give you the slack you need to keep the wires from being trapped/pinched between the gasket and the valve cover.
Did it only run on one bank
Just a PSA, never use gaskets or electrical parts made by Dorman, you will regret it. Dorman has a nasty habit of shortening their tubes and wires by just a bit, and they'll shave a few thousands off their Orings and gaskets as well. Case in point, I purchased and installed a set of Dorman Orings for an oil cooler and the end caps of the cooler slid right on with barely any pressure applied, needless to say once the oil cooler was in place it leaked and I had to redo the entire procedure with oem Orings. Then there was a Dorman radiator return hose I purchased that had a 90 degree bend in it (supposedly a direct replacement for oem) but the hose itself was just about an inch too short to reach the tee at the other end. Save yourself the frustration, the extra money you pay up front for oem (or better quality aftermarket) will save you from the cost of a tow and re-repair down the road. My 2¢.
I’m literally about to change my gaskets and the first thing I heard was dorman and I said hold on a minute and then I see this comment and I was like yeah Not doing that lol- sucks that no one wants to listen to the mechanics (like in this case) but then again don’t blame them because there are some hacks out there
I'm just about ready to replace mine and I've been looking at the aftermarket gaskets and yes I'm guilty of using cheaper parts that have great reviews but I've decided not to in this case. I'm going with all OEM, FOMOCO parts, my girl is a 2000 F-350 7.3l w/211,000 miles. Bought her new and she has treated me well! So she will have the best parts from now on...
Thank you sir. I was about to install the dorman gasket and watched your video. Saved me a lot of headache with it.
Ron - Thanks for the video. Unfortunately learned this one the hard way on the first bank (before seeing the vid, of course). Regrouped, tucked the wires appropriately, and life's good again! Thanks a bunch for the info!!
Great video!!! I’m glad I came across it before I installed the same Valve cover gasket about an hour ago.
Ron Williams, I have the same gaskets you featured in this video and need to point out to the other viewers here that Dorman's product isn't an issue here. Yes, the way the wiring is set up if you aren't paying attention when you install them, you will have wires getting pinched (which will lead to premature failure of those wires). However, there is sufficient slack in the wiring that allows you to easily move them out of the way when you install them in the engine. I think its a stretch to say Dorman has a faulty product, especially when this solution is superior to cutting quarters in order to solve the stock gasket problems.
Those wires were so tight I had to stretch them around the plastic. Epic fail from dorman.
@@SandCarServices well, I didn't have the trouble you faced and this was a job I wrapped up a month ago. It is possible the product has improved.
Def short wires I caught the overlap prior to install but way more tension on wires than should be I had to go to the extent of removing one of the zip ties for some extra slack on each side...
the plastic insulation on the wires is reported to fail quickly. That is a fail for sure!
Dorman is garbage. They use cheap sheathing on the wires and the oil causes them to prematurely fail.
I orderd a set of doorman’s got them in the mail opened them then boxed them and sent them back. You can see bare wire..sooo went to OEM
Great call-out. Always been a fan of dorman products, if not fomoco or motorcraft. I'm surprised international didnt design these gaskets with 1 less plug per gasket with the amount of harmonics these engines create.
Unfortunately it seems the Dormans are the only gaskets available these days. The OEMs are sold as 2 pieces, good luck finding a set of both. The OEMs I did find were made in China too. Thanks for the heads up, I probably would have made the same mistake had I not seen this
Ok update - I just did glow plugs and gaskets on a 7.3 yesterday with dorman gaskets - and they still have the wiring tie wrapped in such a way that will cause it to be shorted just as the video showes - it was a 2001 f250 with 570k miles on it.... the date is 11-12-2019
I have installed this product on my 2001 7.3 and I bent the wires so they would stay away from gasket simply pushing wire is not enough because wire tension can push it back where you don't want it. Did my gaskets about 5 years ago 2019.
thank you im gonna do mine today and just stumbled apon your video this is great info.
i Replaced an old set of dorman valve cover gasket because of the insulation was cracking on the wires.
Hey Ron I just wanted to let you know that I like the Dorman setup. The problem I ran into is that the heat shrink gives out and the crimp area starts to rub into the glow plug wire and shorts out. I installed it on a 02 and had to replace it again 3 months later. I found out the best way to make sure that it does not happen is to use 60/40 solder and fords double insulated oil resistant heat shrink I have also tested it on my own 01 and never had the same problem. It has lasted so far 3 years I have already put 233,000 miles on it now.
Bought some similar from another company recently they were junk, had nicked wires, missing wires and was just plain poor quality for 300 dollars i sent it right back and got some oem ones, they still have that plug under the valve covers but its good quality and it works.
I ran across this years ago. Use the Dorman gasket set to fix leaky valve covers. Cost me another set of gaskets and 1 new injector. Won't do that again !!! 331,000 miles and counting !
One less connector is a good thing. When you first showed that Dorman gasket I though "aren't those wires going to get pinched"? Thanks for the warning. ;-)
Thanks for the tip on pushing those wires down my gaskets don't say Dorman but they do say China so thanks for the heads up
Wow - just in time viewing - have a 2001 7.3 just rolled in with 560k miles on it - customer wants new glow plugs and gaskets and the control relay... I have motor craft glowplugs but dorman lifetime gaskets with the integrated wiring harness - you can bet I will check them tomorrow - if they are still screwed up I will repost ... thanks for the heads up...
I’m having a problem with that set up right now 1, 2 and 3 injections are not firing
Did he any sort of knocking replaced mine with dorman and had glow plug and injector codes then suddenly got a slight ticking
Hi Ron....so, based on the upgraded design, would you recommend the Dorman gasket over the Motorcraft? (assuming, of course, that you position the wires properly).....thanks....Darryl.....
I personally like the Ford gasket over the Dorman.
Awesome video thanks a bunch. Getting ready to do this install
Liked and subbed. I have a 1999 f250 7.3 and love the truck.i had the same problem with my truck with pinched wires and my ICP sensor. I fixed both and runs great.
Is there a different brand gasket you recommend?
Had the same thing happen to be on the company tow truck about 10 years ago and last year I was putting injectors and valve cover gaskets on my excursion and seen that so it wouldn't happen again
Very good and helpful information! Thank you!
I got lucky lost 4 glow plugs to these but no injectors after just being replaced once I get the new ones will be doing this and retesting glow plugs and injectors hope it turns out okay
Bought a dorman valve gasket for my 7.3 install it and it was in short change for oem and solved
Ron Great video God bless you ene were you are from NJ
Cant say I would have noticed that. I'm working on a 94.5 so the harness is different, but I will check to make sure wires are clear when I put the valve cover on.
Can you use that dorman valve cover gasket on early 99? Mine was made 05/99 exact problem with injector #7 and #3 glow plug not plugged. Thank you
Yes
Thanks Ron! Information helped me out
Loved the vid but I know ya knew that from beginning Right? Cause that is a problem that they need to fix but I’m a shade tree mechanic lol and I know I would have caught that. But not trying to be a ass hole at all. Nice video thanks.
I have a question for you that you may or may not be able to answer but I would appreciate it as soon as you get this if you would. The question is the heads on my 2002 7.3 did not have a fuel return and the heads that were rather identical come off of a 96 or 97 I believe 7.3 words to junkyard said that they would interchange however the heads I put on it had a fuel return line so since my original heads did not have a fuel return I just use a plug-in plug them up. The question is would something like that cause me to have performance issues as I put new heads all the injectors are working and I still got a lot of white or gray type smoke coming out the exhaust thank you for your help I do appreciate it
That's not a simple question to answer
Any help is greatly appreciated
Why were the heads replaced?
Thank you my friend very helpful
Just had this issue and found that exact pinched wire. The wire does not look damaged though. Did you have to replace the gasket/pinched wire that was pinched or were you able to reuse the same gasket??
Replaced it.
Fuck!
Was your wire visible damaged? Mine just looks a little pinched.
So fucking pissed off .
I watched this video before I did this then showed my brother it then reminded him several times to make sure not to punch that wire when you put them on.
Truck was running fine for like a week then started it up today and it runs like shit
Took the valve cover off one side and sure enough pinched fucking wire right there
Does the original Ford plug plug into the Dorman valve cover gasket or do you have to rewire a new plug to plug into the gasket
Excellent question. Its direct fit. Dorman does give you a pigtail incase you need it.
I don't know for sure as I haven't done the install yet myself. But from all the videos I've watched and the included parts when you order these kits it looks like you'll have to wire in a new pigtail that will connect to the dormant gasket. After doing some more research I found a comment on an amazon review of the doorman kit and the customer reported using his old pigtail as it was good still.
So I have a question and this has been kicking my ass. When replacing the valve cover how do you plug the white glow plug wire back in? This has been fighting me for the past couple of days. I’ve tried everything I can think of. It’s gotten to the point I’ve had to buy another gasket because I’ve broken the white wire that plugs into the glow plug. Please feel free to reach out to me. Thanks for your help. Jason.
Hey Jason- those plugs fit pretty tight - what I do is get a nice size screwdriver on th back of the plug - when it is in place just give the screwdriver a rap and the plug will slide - just a little impact will make it go on. Good luck
I used some pliers to push them in they are a pain in the ass
Great Video, Thanks!
So what would you recommend? Dorman and be careful or OEM motorcraft gasket and harness which are separate part numbers?
Either way, OEM is almost always better.
Always buy Powerstroke parts (or parts for Lincoln, or any Ford) directly from Ford or you will have to buy them again very soon when they fail. I speak from personal experience as an owner of Jaguar (Ford product), and as an owner of a 7.3.
Great information. Thank you
I’m having trouble finding the Motorcraft part numbers for the gasket and harness. Anyone know what they are?
GUYS!!!! do not use these! I put them on my 2000 7.3 and the glow plug pin burnt off inside of the connector. also the rear cylinder on passenger side injector clip fell off of the injector while running. lasted 10 months and I don't drive it a lot. only ford parts on these! I had to but FOMOCO gaskets and the inner injector harness. My connectors to the engine harness were still good! I'm a 34 year ASE master tech! FOMOCO parts only on these!
I agree
What brand of injector orings do you use.
Motorcraft only
Very helpful videos
Would a bad injector solenoid ground out the entire bank on a 2003 7.3 powerstroke. Have changed the IPR and IPC along with UCVC Gasket and the IDM tested good.
I haven't seen that happen
Thank you for sharing.
Sorry...IMHO, the Dorman gasket is a better design IF you pay attention to the installation. You need not deface currency, and you don't have to worry about spare change in your valve cover. I've been"riding" a pair of theses gaskets for almost 4 years without any issues! With ANY automotive procedure, you need to watch for pinched wires (including the ones you're not working on).
Besides the wire getting pinched in the Dorman harness has there been any other issues with them ?
I have not seen any problems other than that. The wiring under the cover can not come loose at gasket again because they eliminated the connection
@@SandCarServices So the Zip ties should be fine for that higher heat and oil region?
@@samuelyi9189 Yes. i have ran mine for over 100k miles with zero problem.
@@rhettbachofer8824 Nice. I put in some and made sure the wires didnt get pinched. Was very helpful tip. If only i had glow plugs on hand at the time. Lol
Samuel Yi will this cause a idm code if a wire gets pinched or the connector separates ?
This gasket should work for all 7.3 if you go to the auto store it should be able to cross reference all the years from 94 to 2003.
No 94.4 -97 have a 4 plug gasket
Great video thanks
Very helpful video! My normal source of parts is Rockauto and I see they carry 3 brands that come with the wire harness -- Standard, Apex, and GB. The pictures show only the GB one with ty-wrapped wires and the other 2 are loose wires. They also sell the gasket alone no wires. Anyone use any of those brands?
Nice video
Zip ties are not a good idea where there is any heat. Those should be removed.
I agree, but I dont do that.
Can't ever blame the installer!
On all my ford fleet all i willingly put on is oem
>>WARNING * CHINA SELF DESTRUCT UNIT
Thanks for the info. That would make sense
You couldn't pay me to use Dorman engine parts on my 7.3 Powerstroke. I use OEM and know it will last another 200K miles.
👏👏👏👏👏
i used china-ized aftermarket they lasted 3 year before they broke.
Wouldn't that be common sense?
👍
Dumb as a door if you use doorman lol
The design is fine. It's always up th ehe mechanic to install correctly. I call BS on your excuse
Pretty obvious to see that during installation.
great info very helpful