Okay guys, I know there are several topics out there that cover this in a round-about way, but I'm in a time crunch, decision wise, so I'm posting a new topic. I have the opportunity to buy a complete '91 Dodge 3/4 ton with a 12v 6BT with 71k original miles and a 5 speed manual, which has some sort of damage to the tranny which I have not been able to inspect yet. Anyway, I can likely get the complete truck VERY, VERY CHEAP, but time is of the essence. I'm looking to find out what transmission options I have, or should consider. Can the stock Dodge transmission be used in my truck? Were they using New Ventures back then too? I assume both for mounting and gearing, my stock 4 speed with "granny" first is not going to work or be an option? I'm considering a ZF6, because I like the manual and that's obviously what I have now. Does anyone know if I'm just looking at mount issues or will I have to rework the tranny tunnel and/or firewall for this trans? Can I use my existing transfer case on the ZF6? I assume there are some electrical factors with using this tranny? It seemed I remember hearing that if I went with this I would need a newer rear end as well? But that may have been something to do with when I was looking at doing a commonrail cummins?

I've looked at fordcummins.com before, when I originally looked at this conversion, but I haven't called them yet. I saw destroked mentioned in a couple posts, and superior motor mounts etc, but I don't see they offer a 12v motor mount kit for my '86? It looks like adapter plates are readily available for the ZF6 or even ZF5 for the 12v motors, so that should be easy enough.

I'm sure there are about 20 questions I can't think of at the moment, as I'm posting this from my phone while at work, but I wanted to get the thread rolling. Let's say I could get the truck complete for $500 (I know, I know...!!), it looks like a ZF6 is about $2k average, unless I can find one junkyard local, adapters are about $1500 total is appears. Other major items I might be overlooking from guys who know or have done this swap? Driveline work I know, but I can have done local and relatively minimal cost in grand scheme.

Thanks for the help!

 

I am doing some research on this myself and I am pretty sure the trans is going to be a Getrag. I have read on a few sites that the Getrag has a bad rap and with updated rebuild parts can be made reliable. I also found that although readily avaialable the ZF adapters are pricey. I think as far as a diesel swap you can't go wrong with the Cummins. There are several 80-86 cummins swaps out there one in particular, I think he posts under "browntruck" had a pretty detailed writeup floating around.

 

https://www.ford-trucks.com/forums/5...-kit-ford.html

YouTube - rmbone71's Channel

YouTube - 1986 ford F350 crew cab cummins swap

 

I am sitting here, should be working, but I've pretty much convinced myself I should buy this donor truck and engine. My truck is In VERY NICE condition and the 460 is still strong with 195k on it, but I could likely get at least another 5 years of great use out of it with the cummins before I will really want something a bit newer. Realistically I could get that or more out of it as is, but I'd love to get much better mileage empty and when loaded for the dunes! 8 MPG when towing isn't much fun!

Please let me know your input on the other questions though, as I want to start thinking the project out in advance!

 

You can get the donor truck for $500. Jump on it. You can resell it for more than if you change your mind. I'm getting 21-24 mpg on my 85 F350 Crew cab with a 6BT,& Getrag 5-speed, which is a daily driver now. I no regrets.

 

Mark,
I would practically kill for any pictures you have of the process and finished product! Is the Getrag the stock tranny in some of the dodge's? The truck has a 5 speed in it currently, that as mentioned has some sort of issue with it. As far as purchase price goes, I was going down the same road, figuring if I do end up getting it for that price, possibly cheaper even, that I could easily part out and make money, even if I didn't do the conversion. I'm starting to do more towing and with my commercial fuel card, I can get diesel for almost the same price as regular and I will get better mileage and at least equal pulling to my 460, before I even start twisting/tweaking on the 6BT.

 

Okay so my brain is going faster on this swap than I've actually had time to physically verify here... So the donor truck, complete, has a Dana 60 under it at the present time. I've been searching, trying to determine if the Dana 60 that would be under a 1991 Dodge 250, is the same or differing track width that would have come under the F350's of similar vintage. Here's my thought, if the Dana 60's are the same width, could I do the Dana 60 swap, utilizing the passenger side layout of the Dodge front end, thus allowing me to swap the 5.9, Dodge (Getrag correct?) 5 speed and transfer case in? I'm guessing I would need the steering components and hubs etc off an F350 Dana 60, to put on the Dodge unit? If I can utilize the engine/transmission combo, along with the Dana 60, it seems like it could save a lot of hassle with $800 adapters and $2000 ZF6's? Help me out guys?

 

It should all bolt in pretty much close to direct. Your F350 has twin traction beam with dana fifty more than likely. You want to ditch this as it eats tires, and has trouble bigger than 35s. Dana 60 is many times better as its solid.

 

The following two sites have a ton of info. (The 4BT is basically the same as the 6BT, just without two cylinders.)

Check out the tech articles a the cumminsforum for first gen. Dodge cummins

Dodge Cummins Diesel Forum
http://www.4btswaps.com/

 

Thanks Mark, I will definitely try out the Cummins site, because I also have questions on the Dana 60's under the Dodge's, 91 specifically. I actually created a separate post under the axle, transfer case etc forum here:

https://www.ford-trucks.com/forums/1...ml#post9684651

I'm trying to determine track width differences between 91 "dodge" Dana 60, same vintage "Ford" Dana 60 and my D50 TTB. I was thinking about trying to use the front axle, Cummins, tranny and transfer case out of the donor, effectively converting my truck to a Dana 60 but with passenger side diff? OR, the other option would be if the Dodge is a divorced transfer case, mating the Dodge tranny to my transfer case and keeping the TTB for now on the driver's side and possibly later swapping a "Ford" Dana 60 in? How do the D50 TTB's compare, track width, to the D60's in the F350's in the late 80's early 90's trucks?

Sorry guys, I know I'm hitting a lot here and I will admit, I'm having to decide on things so fast, I'm having trouble keeping up with thoughts and options.

 

Send a pm to 89ford73. He was the one who was able to answer all my questions because he has done the swap before.

 

Thanks I'll give it a shot on th PM. I'm pretty sure I can make some configuration work with the donor truck and my parts. Going to crawl under mine and then the donor this afternoon and check some stuff.

 

Mark,
What transmission are you running behind your 6BT? I'm still trying to figure out if I can use the Dana 60 under the front of the donor truck, with the passenger side driveline/diff. If I can, I'll just use the engine/transmission/transfer case and have a passenger side diff/driveline in the front. However, I need to figure out if the fixed portions of the Dodge are the same dimensions as the Ford, allowing me to use the main body of the "Dodge" Dana 60 and put the ford knuckles, spindles etc on it for compatibility. The other option I just thought of after reading some other articles would be to mate up a NP205 for a Ford, swapping out parts from the Dodge 205, so that I have a Ford NP205, with driver's side diff, but with the 29 spline compatibility to use the Getrag that is in the donor.

Does this all still make sense?

 

I'm telling you I would PM 89ford73 he answered all these questions for me because he has acouple of these trucks and has done the swap himself more than once.

 

Alright, I PM'd 89Ford73. That said, I'm pretty sure I've figured out what I "should" be able to do. Transfercase guys help me out here... Dodge and Ford both used 6 bolt NP205's, so what I am planning to do is: pickup a Ford NP205, I've located a couple already, put the adapter currently mated to the Getrag 5 speed and Dodge NP205 on the front of the Ford NP205. Then, because both the Dodge NP205 in the Cummins manual trucks and the Ford NP205's are large bearing, I can swap the 29 spline input in to the Ford NP205, allowing my Ford NP205 to spline up with the Getrag tranny and by using the Getrag to NP205 adapter currently mounted on the Dodge NP205, everything should bolt up? Did I lose anyone? This will give me the cummins, Getrag, Dodge/Ford NP205 with driver's side driveline drop, allowing me to keep the D50 TTB currently in my truck for the time being and can still do a D60 swap down the road?
Need a little reassurance that I'm not totally lost in my thoughts guys? My only question is confirming that the 6 bolt pattern on the transfercase should be the same on the Dodge or the Ford NP205. I.e. the thought that I can use the Dodge adapter on the Ford NP205.............