Top Upgrades for the 7.3 Powerstroke
Boost Power, Reliability, and Longevity with Proven Diesel Upgrades
The Ford 7.3L Powerstroke diesel engine is one of the most legendary powerplants in diesel history. Known for its simplicity and long lifespan, the 7.3 is a favorite among truck owners, ranchers, off-roaders, and performance enthusiasts alike.
But even the toughest engines need attention, especially if you’re towing, tuning, or just trying to make your Powerstroke last another 300,000 miles. If you’re ready to upgrade your 7.3, Choate Engineering Performance offers some of the best diesel parts and packages in the industry.
In this guide, we break down the top 7.3 Powerstroke upgrades we offer, and recommend, for those building for reliability and power.
1. Billet Connecting Rods
If you’re looking to prepare your 7.3 for more power, or just looking to extend the life of your engine, consider upgrading to Carrillo Connecting Rods.
Why it Matters:
Early 7.3 Powerstroke engines came with powdered metal connecting rods (PMRs) , which are prone to failure under heavy tuning or towing loads. Forged OEM rods were more likely to bend rather than snap. The Carrillo rods are even stronger and more durable, making them a better candidate for withstanding the stresses of high performance applications. The Carrillo rods are also known for their longevity, especially when your engine is not completely stock.
2. Coated, Flycut & Delipped Pistons – A Critical Upgrade
Coated, Flycut & Delipped. These aren’t just buzzwords used by performance builders — they’re critical upgrades that solve real-world weaknesses in the 7.3’s internal design. Our 7.3 Choate Pistons improve performance, durability, and longevity. How do they do this?
- Polyphen Coating – Help reduce heat
- Flycuting – Allows for larger cam
- Delipped Fuel Bowl – Helps prevent cracking
You can learn more about why our pistons are essential upgrades here.
3. Top-End Reliability: Cylinder Heads, Valve Train & Head Studs
The stock 7.3 top end can hold up well — until it doesn’t. For tuned builds or trucks under load, upgraded valve train and cylinder head components are a must. The Cylinder Heads on the 7.3 play a key role in engine performance, housing the valves, valve springs, and other valvetrain components. Our Choate 7.3 Cylinder Heads are resurfaced to maximize sealing surface performance, include all new parts for essential components, and use threaded “blow proof” plugs to help prevent cylinder head failure.
Choate Top-End Recommendations:
- Ported Cylinder Heads – Improved airflow and cooling
- O-Ringed Cylinder Heads – Significantly reduces the possibility of head gasket failure
- ARP or Gator Head Studs – Keeps head gaskets sealed under pressure
- Upgraded Pushrods – Ensures precise valve timing and improved engine efficiency
- Upgraded Valve Springs – Provide strong valve control under high stress
4. Balanced Rotating Assembly – The Unsung Hero of Reliability
Balancing is a critical step to a successful engine build. Anytime you’re rebuilding your engine, you should balance the rotating assembly. By carefully matching and balancing the crankshaft, rods, and pistons, Choate Engineering is able to reduce vibration for smoother operation, reduced wear, and better performance.
Benefits:
- Less Engine Vibration
- Lower Bearing and Crank Wear
- More Efficient Power Transfer
You can learn more about the benefits of balancing your rotating assembly on your next build here.
5. Billet Girdle – A Smart Upgrade
Though the 7.3 Powerstroke is often praised as one of the most reliable diesel engines ever made, when you start adding power –whether for towing, daily driving, or racing — you begin to uncover the factory limitations, especially in the bottom end of the engine.
Arguably one of the most cost-effective upgrades for a performance or rebuilt 7.3 is the addition of a Billet Main Girdle. A billet girdle is designed to minimize the risk of stress factures or cracks in the engine block associated with high horsepower levels.
The Kit We Offer Includes:
- Billet Main Girdle
- ARP Main Studs
- Washers & Nuts
- Oil Pickup Tube Tab
You can learn more about why you should consider adding a Billet Girdle to your build here.
6. Billet Freeze Plugs – A Must-Have Upgrade
While often considered a minor part, the freeze plug plays a crucial role in your 7.3’s cooling system and engine block integrity. The factory-installed soft plugs can become a serious weak point — especially under high pressure, heat, or when making big power. Our billet freeze plugs come with an o-ring seal and blackplate for a more reliable fit, giving your engine a long-lasting solution to factory freeze plug blowouts. Our 7.3 Billet Freeze Plugs are made of billet aluminum, meaning they won’t corrode away like the standard stamped metal ones are prone to do.
Our Freeze Plug Kits Include:
- Aluminum Blow Proof Plugs
- Buna O-Rings
- Stainless Steel Hardware
We are so confident in our 7.3 Billet Freeze Plugs that we install them in all of our 7.3 Choate Engines. You can learn more about our Billet Freeze Plugs here.
Why Choose Choate Engineering Performance?
What separates Choate from other engine builders? It’s our obsessive attention to detail. All of our engines are:
- Blueprinted and Balanced
- Built with upgraded, tested components
- Machined in-house with tight tolerances
- Tested to handle real-world abuse
From Daily Drivers to 700hp builds, Choate’s engines are trusted by diesel shops, ranchers, and performance enthusiasts nationwide. You can explore our full line of 7.3 Powerstroke engines, parts, and rebuild kits here.
FINAL THOUGHTS
The 7.3 Powerstroke may be one of the most reliable diesel engines ever made, but there’s always room for improvement. Whether you’re looking for more power, better towing reliability, or long-term peace of mind, Choate Engineering Performance has the parts, engines, and expertise to get you there.
Upgrade smart. Build strong. Trust Choate.