The Ford Power Stroke engines, specifically the 7.3-liter including models produced between 1994 and 1997, have earned a reputation for their robust performance and longevity. However, as with any truck, there are always areas where aftermarket enhancements can lead to significant overall improvements. One such area in that 1994-1997 OBS variation is the fuel system. Although reliable for its time, the stock mechanical fuel pump located in the engine’s valley has shown its vulnerabilities over the years, particularly concerning leaks, maintenance, and long-term longevity issues. A Power Stroke OBS electric fuel system conversion kit will cure these woes.

Eliminating the stock mechanical pump will be a real game-changer when it comes to upgrading that old Ford truck and really help reach its maximum potential. The stock mechanical pump in the 1994 to 1997 Ford Power Stroke was functional but has several drawbacks that the Driven Diesel system effectively addresses. Mechanical pumps are driven by the engine, meaning their performance is directly tied to engine speed. This dependency can lead to drastic fuel pressure and fuel volume variations, especially at lower RPMs, which affects engine performance. Mechanical pumps are also more prone to leaks and failures due to their moving parts. Over time, the seals and gaskets in a mechanical pump can wear out, leading to fuel leaks and a failure that leaves you on the side of the road.

Driven Diesel, based out of Phoenix, AZ, has focused primarily on the Power Stroke market for over two decades. It has addressed these shortcomings with its many variations of electric fuel system conversion kits. With options for everything from a basically stock truck to all-out performance and even competition-only trucks, they are sure to have the perfect fuel kit for your needs. 

With the majority of the 7.3-liter market still being daily drivers, tow rigs, and work trucks, the most popular system is their V2 Complete OBS Electric Fuel system that includes a single Bosch fuel pump and features components such as the machined billet fuel filter heads, high-quality Baldwin filters, CNC bent stainless lines, and their industry-leading regulated return kit for a complete tank to engine installation. Not only is it a complete system capable of supporting 350 to 400 horsepower without pressure drop or fuel volume concerns, but it’s also 50-state emissions compliant with a CARB E.O. number.

Let’s go over a few of the specific items found within the kit, setting it apart from other options on the market and why it’s an excellent setup to replace your factory mechanical pump.

Bosch Fuel Pump

The included Bosch fuel pump is a massive leap in efficiency over the stock mechanical pump and is the same unit Ford engineers used in the 1999-2003 7.3-liter Super Duty. At the heart of this fuel system, the Bosch fuel pump offers better fuel flow, more consistent pressure, and unbeatable reliability. If Ford believed this pump was exactly what their ‘99 to ’03 trucks needed, there is no reason to question its place on the frame of your 1994 to 1997 truck. Renowned for its precision engineering and reliability, this Bosch pump was designed and developed for diesel fuel, not gasoline, and provides ample fuel volume for that 7.3-liter engine staying under or around the 400-rear-wheel-horsepower range. For guys shooting for 400 to 600 horsepower, look at upgrading to Driven’s dual pump kit, which is also available.

Machined Billet Fuel Filter Heads

Durability and precision are another critical component of the Driven Diesel Electric Fuel Systems, which was the driving reason they opted to develop their own filter head bases rather than use the cheaper cast aluminum heads found in other kits. The proprietary billet fuel filter heads are machined from high-quality aluminum with exacting specifications to maximize fuel flow and fitment. 

The commonly used cast aluminum bases used by competitors on the market are imported from overseas, are not known for their exact specs, and have been known to crack and fail over time. So, the use of billet aluminum bases that Driven Diesel developed ensures that the system runs trouble-free and smoothly, even under demanding conditions, for hundreds of thousands of miles.

High-Quality Baldwin Filters

Ensuring clean fuel gets to the engine is paramount to its performance and longevity. The Driven Diesel Electric Fuel System includes high-quality Baldwin filters that effectively remove contaminants from the fuel long before it reaches the injectors. These filters were designed to meet and exceed OEM specifications, ensuring that they provide superior filtration. By trapping dirt, rust, and other particles, these filters protect the sensitive components of the fuel injection system, such as the injectors and fuel pumps. This protection not only extends the life of these components but also ensures that the engine runs efficiently, with lower emissions and better fuel economy..

Regulated Return Kit That Stands Out

One of the standout features of the Driven Diesel system is its regulated return kit. On the market for 20 years, it’s gone through quite a few revisions. This kit addresses issues found in the stock 7.3-liter fuel system to offer the best fuel flow possible. The factory system can cause inconsistent fuel pressure and excessive heat in the fuel before it enters the injector. All of this can lead to uneven injector performance and the potential for injector and even engine damage over time. 

The regulated return kit maintains a consistent fuel pressure across all eight injectors by using a consistent fuel pressure set by the adjustable Fuelabs regulator mounted atop the engine. This setup ensures that each injector receives the same amount of fuel at the same pressure, optimizing combustion and improving overall engine performance. 

The electric fuel pump also powers up when you turn the key on, so while you have the “Wait to Start” on the dash, the fuel system fully pressurizes and eliminates the need to wait for a mechanical fuel pump to make pressure when you start cranking the engine. The biggest thing you’ll notice is quicker engine start-up, better throttle response, a smoother engine will idle, and you may even notice a slight quitter engine, something the 7.3-liter hasn’t been known for.

The transition from mechanical to electric fuel pumps offers numerous advantages. Electric fuel pumps provide a more consistent and higher-pressure fuel flow, which is crucial for modern diesel engines. This consistent pressure ensures that the fuel injectors receive an optimal supply of fuel, enhancing combustion efficiency and engine performance. Furthermore, electric pumps are less prone to wear and tear and usually outlive the mechanical pump you’re replacing. Reducing the frequency of maintenance and the risk of leaks is also a common issue with the stock mechanical pump; you’ll find it hard to convince yourself to make the switch.

By eliminating the pressure variations that can occur in the stock system, the electric fuel pump and regulated return kit help to balance the load on the injectors, reducing wear and tear and extending their lifespan. Additionally, this consistent pressure can lead to smoother engine operation, with fewer instances of hesitation or power loss.

Eliminating the stock mechanical pump will be a real game-changer when it comes to upgrading that old Ford truck and really help reach its maximum potential. The stock mechanical pump in the 1994-1997 Ford Power Stroke was functional but has several drawbacks that the Driven Diesel system effectively addresses. Mechanical pumps are driven by the engine, meaning their performance is directly tied to engine speed. This dependency can lead to drastic fuel pressure and fuel volume variations, especially at lower RPMs, which affects engine performance. Mechanical pumps are also more prone to leaks and failures due to their moving parts. Over time, the seals and gaskets in a mechanical pump can wear out, leading to fuel leaks and a failure that leaves you on the side of the road.

Installation of this kit can be a little labor-intensive as turbocharger removal is required for access to the fuel fittings in the back of the cylinder heads. It’s worth noting that the long-term benefits of installing the Driven Diesel Electric Fuel System will far outweigh the time spent bolting it up. This also makes it a great time to replace exhaust up-pipes that are more than likely leaking and affecting turbocharger performance. The process is straightforward, and the color picture instructions accessible through a QR code for viewing on your phone are second-to-none. With all the necessary components, this is a manageable project for most experienced mechanics.

The primary long-term benefit of the Driven Diesel system is its reliability. By eliminating the problematic mechanical pump and using high-quality components, the system reduces the risk of fuel system failures, which is especially important for vehicles used in demanding applications such as towing or hauling.

Another significant benefit is the improved engine performance when you’re modifying that truck for more than stock power. With a consistent and high-pressure fuel supply, the engine can operate more efficiently, leading to better power delivery and fuel economy. This is the ultimate fuel system for a truck running stock and Stage One injectors but also offers versatility to the future with optional upgrades. 

Should your goals change later in life and you install larger injectors, this system can easily be upgraded to the Dual Pump Kit to supply fuel volume for 400-plus horsepower. Drivers will notice smoother idle and acceleration, a more responsive throttle pedal, and potentially even quieter engine operation. A consistent fuel pressure provided by a Regulated Return Kit is frequently highlighted as a key advantage. When bumping pressure up to 65 psi, the 7.3-liter is just happier, leading to more reliable engine performance, especially under load.

Conclusion

A worthwhile investment, the Driven Diesel Electric Fuel System represents a significant upgrade over the stock fuel system. By incorporating components such as the Bosch fuel pump, machined billet fuel filter heads, high-quality filters, CNC stainless steel lines, and the industry-best regulated return kit, Driven Diesel has created a system that enhances both reliability and performance for the OBS Ford. Eliminating the troublesome stock mechanical pump addresses a common weak point in these vehicles, leading to fewer maintenance issues and a more consistent fuel supply. 

For owners of 1994 to 1997 Ford Power Strokes, investing in the Driven Diesel Electric Fuel System is a worthwhile decision that can extend the life of your engine, improve performance, and provide peace of mind. Whether used for daily driving, towing, or heavy-duty work, this upgrade ensures that the venerable 7.3L Power Stroke continues to deliver outstanding performance for years to come.

To learn more about the complete Driven Diesel line of fuel systems, visit Strictly Diesel’s website. You can also visit their blog page for more in-depth Power Stroke Fuel System articles explaining how and why they’ve developed the products they offer.