Originally Posted by MadScience
I do know that at 3k miles you're due for an oil change. The high pressure system driving the injectors will sheer the oil down to where you really can't run it much longer than that. I have no idea if that engine has any sort of a reminder system. The gas engines of that era didn't.
The 7.3 doesn't sheer oil anything like the 6.0 does. The reason the 6.0 "sheers" oil is because it's German engineered with real tight tolerances, and runs at much higher pressures. 3,000 miles is nowhere near an oil change emergency for a 7.3, considering that these vans are de-tuned 80 hp and most aren't used like a heavy tow rig. My 2003 is rated at 9400 lb. GVWR and 9600 lb. towing capacity! When I tow like that, then I'll change it at 3,000! Most of these vans aren't above 8,500 lbs. fully loaded for a trip. With 15 qts. of Rotella or Delo 15w40, and light/highway use, 5,000 would be my maximum. I run full synthetic and go up to 6,000 because I send in oil samples and they're remarkably clean. The OP should consider getting scanned for code, as suggested, so the source of problem is known and corrected.