99+ Ford SuperDuty to Cummins Engine- Overview
What does it take to put a Cummins engine into my 1999 + Ford SuperDuty?
6.0 Powerstroke problems? |
That's right, we can help you solve your "6.0 Powerstroke problems" by sending you a Ford Cummins 6.0 replacement installation package of custom parts. See CONVERSION INSTALL PACKAGES chart bellow.
If you are planning on doing the Cummins 6.0 swap or changing out a 7.3 or even gas engine, the following information will help you to gain a better understanding of the overall conversion.
The Cummins swap into the 99 and newer Ford SuperDuty is perhaps the easiest physically 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 order from us are the engine mounts, alternator regulator, bushing kit, tachometer kit (if applicable), and the transmission adapters.
You will use the stock Ford diesel or V10 radiator. 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 and not have to do drive line modifications. Sometimes 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:
For the automatics from behind the 5.4 V8 and the 6.8 V10 gas engine trucks as well as the 5R110 Torqshift (03+), our Adapter Plates use the Ford 6.0L diesel starter. The same is true for the 03 and newer ZF6spd. For the trucks that had the 7.3 Powerstroke diesel, our custom Adapter Plates use 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 the manual). [Note: Not all Ford transmissions require this same trimming, some older ones more, and some newer ones less. There is no trimming required for the 6.0L 5R110 TorqShift, the 5.4L 4R100, or the 6.8L 4R100 transmission bell housings.] You will 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 non-electronic (explained in installation manual).
24V: This Cummins engine does have a computer, but is not too bad to wire as we send you instructions 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 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.])
Print a PDF version of preliminary information for your conversion:
*click here to print PDF of 99-02 Ford Super Duty general conversion information
*click here to print PDF of 03-07 6.0 and 5.4/6.8 general conversion information
For more detailed information on the rest of the Ford Cummins diesel conversion see the Installation Manual.
ORDER NOW : INSTALLATION MANUAL-Cummins into '99+ Ford Super Duty
CONVERSION INSTALL PACKAGES
*click on the blue price to see parts lists |
12 valve Cummins 6bt 1989-1993 (Dodge App.) | 12 valve Cummins 6bt 1994-1998 (Dodge App.) | 24 valve Cummins 6bt 1998-2002 (Dodge App.) | Commonrail Cummins 6bt (2003+) (Dodge App.) |
| Ford 2003-2006 | ||||
| 6.0 Powerstroke Diesel / A.T. 5R110 TorqShift | $3,535 | $3,535 | $3,859 | $3,545 |
| 6.0 Powerstroke Diesel / M.T. ZF 6spd | $2,734 | $2,734 | $3,059 | $2,740 |
| 5.4 Triton V8 / A.T. 4R100 [2003-2004] | $3,329 | $3,329 | $3,648 | $3,335 |
| 5.4 Triton V8 / A.T. 5R110 TorqShift [2005+] | $3,534 | $3,534 | $3,798 | $3,540 |
| 6.8 Triton V10 / A.T. 4R100 [2003-2004] | $3,329 | $3,329 | $3,648 | $3,335 |
| 6.8 Triton V10 / A.T. 5R110 TorqShift [2005+] | $3,534 | $3,534 | $3,798 | $3,540 |
| Ford 1999-2002 | ||||
| 7.3 Powerstroke Diesel / A.T. 4R100 [1999-2001] | $3,003 | $3,003 | $3,322 | $3,014 |
| 7.3 Powerstroke Diesel / M.T. ZF 6spd [1999-2001] | $1,903 | $1,903 | $2,167 | $1,914 |
| 7.3 Powerstroke Diesel / A.T. 4R100 [2002] | $3128 | $3128 | $3,447 | $3139 |
| 7.3 Powerstroke Diesel / M.T. ZF 6spd [2002] | $2028 | $2028 | $2108 | $2039 |
| 5.4 Triton V8 / A.T. 4R100 | $3,204 | $3,204 | $3,523 | $3,215 |
| 6.8 Triton V10 / A.T. 4R100 | $3,204 | $3,204 | $3,523 | $3,215 |
These packages include our Transmission Adapters to use your existing Ford transmission, bolt-in motor mount sets with insulators, and adapters to help you to keep your stock Ford dash. If you are running a 12 valve or early 24 valve Cummins, your package includes parts to help you relocate your turbo. If using an '03 or newer Commonrail Cummins, your package price includes us re-working your Ford engine wiring harness in order to allow you to run the Commonrail.
