99+ Ford SuperDuty to Cummins Engine- Overview
What does it take to put a Cummins engine in my 1999 + Ford SuperDuty?
Here is some information to better prepare you for this Ford Cummins diesel conversion. Necessary parts are highlighted.
This Cummins swap is the easiest so far because there is more room under the hood in this particular Ford truck. You will use the engine components that are already on the Cummins engine (Alternator, A/C Pump, Power Steering Pump) The main custom parts you will need are the engine mounts, alternator regulator, bushing kit, tachometer kit (if applicable), and the transmission adapters.
You will use the Ford radiator no matter what engine the donor truck had. If the Truck had a Ford diesel, then you will also use that intercooler. (If it is a gasser, then just install a Ford diesel intercooler from the same truck.) If the donor truck had a diesel, you will need a Ford throttle pedal and cruise control servo from a gas version truck.
Gauges
We provide you with a bushing kit that will help you install your Ford oil pressure sensor and your Ford temperature sensor units into the Cummins engine so that you can simply plug them back in to your existing Ford engine harness.
Revision To Be Made:
To the Ford Truck:
- No fire wall revisions are necessary to the Ford truck.
- In some cases there is a bit of drive line length adjustment to be made. However, using electric fans will give you enough room in front of the engine to leave the transmission cross member in its stock location. Some times height adjustments need to be made to the rear cross member (even if it does not end up moving back).
- If your gear ratios are 4.10 or lower, you may consider a higher set (such as 3.73's or whatever similar ratio is available for your particular truck).
To the Ford Transmission:
Our custom Ford Cummins Adapter Plates use the your existing Dodge style starter that is already on your Cummins diesel engine. The starter ends up in almost the same place that the Ford starter was, only it has to be a little bit higher. This requires you to trim your bell housing where the starter will otherwise hit (as illustrated in manual). [Not all Ford transmissions require this same trimming, some older ones more, and some newer ones less.] You will also need to trim the Cummins engine block a little bit in one place to allow the starter to go into the adapter plate straight. (also illustrated in manual).
Wiring:
12V: This Cummins engine is easy to wire as it is completely manually operated. (explained in installation manual)
24V: This Cummins engine does have a computer but is not too bad to wire as we send you a simple instruction sheet with your 24V Cummins engine mounting kit that will help you get the job done.
CommonRail: This Cummins engine is fully electronic and is a little more complicated. However, we will help you out by rebuilding your Ford engine wire harness so that it plugs into the Cummins engine wire harness. If you are wanting to use a CommonRail we suggest using either a 2003 Cummins engine or an early 2004 Cummins engine for easier installation. (With these earlier CommonRails you can usually hook up the Ford cruise control servo [from a Ford gasser if you presently have a Ford diesel.])
For more detailed information on the rest of the Ford Cummins diesel conversion see the Installation Manual
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