GReg

DIESELSITE 203* Thermostat 203* (1996 (Engine Serial #201681)-2003 7.3L Powerstroke Thermostat) @ $35.99
http://www.dieselsite.com/index.asp?PageAction=VIEWPROD&ProdID=186

Black Billet Aluminum Thermostat Housing (1999-2003 Ford 7.3L ONLY!) @ $46.85
http://www.dieselsite.com/index.asp?PageAction=VIEWPROD&ProdID=188

During a live tuning session with Jody at DP Tuner last summer, he said that the oil temperatures were getting pretty high without any load and recommended *not* running the 203F thermostat during the summer or when running a heavy load to prevent engine damage due to excessive heat. I tried running a light load (empty 2-axle enclosed trailer) on a 45F-50F day with one of his towing tunes and my engine overheat light did come on. To be fair, I was trying to hurry that day so I was hauling up and down pretty large hills at about 78mph on the interstate. I backed off to 65-70mph and the light went out within 15-30 seconds. I had no other issues during that 4-hour drive.

I assume you are referring to the larger Racor 1000 shown on this page?
http://www.goldenfuelsystems.com/products_fuel_filters.php

I’m running two of these Racor 1000 filters (one on each 60-gal GFS Trekker tank) and have had numerous problems with the custom internal heaters/thermostats. I replaced several before abandoning them completely. It turns out that I’d run my tanks low enough that the heaters were no longer submerged in liquid. When this happens, the thermostats are not effective and the heaters essentially burn themselves out. GFS stopped selling the internal heaters with custom thermostats and I was unable to find replacements. For what it’s worth, the heaters are from Racor and the custom thermostats are called “disc thermostats”. I just couldn’t find a source. The source GFS used was no longer available. Even an engineering person at Racor was aware of the custom thermostats, but didn’t know where to find them.

GFS now recommends external heaters and custom cut foam that wrap around the outside of the Racor 1000. They claim that the oil passing through the filter is heated just as well with these external heaters as it was with their custom internal heaters. The external heaters use less power but the foam wrap/insulation makes them more efficient. GFS did say that I can *NOT* run their internal heaters with the foam wrap because they generate so much heat that internal components of the Racor filter would actually melt. I’m guessing that means you shouldn’t run the internal heaters with an even higher thermostat.

I only have to change my stock fuel filter at normal maintenance intervals (10k or 15k?). Are you saying that you have to change your factory fuel filter regularly? The only time I had to change factory fuel filters early was the first time my Racor 1000 internal heater died. I didn’t realize what was happening, but my fuel pressure gauge was showing 60psi, then gradually dropped to 50psi-40psi-30psi-20psi. Changing the fuel filter temporarily resolved the problem. I replaced the filter several times before I finally realized the Racor heater had died. I figured this out when my fuel pressure dropped to 20psi and returned to 60psi after I left the truck idle for about 10-15 minutes.