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Old 02-04-2014, 11:07 AM
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6.0 to 12v Cummins swap

Well, the 6.0 has served me well, but it has come to a point where I think I am monetarily ahead to swap in a 12v Cummins than to "fix" the 6.0 to keep it going.

I just took delivery on a 12v 5.9 Cummins yesterday. Plan is to tear it all apart to inspect. Assuming the short block comes out good, ie, no chewed up bearings and they all plasti-gauge ok. It's getting put back together with upgraded injectors, turbo housings, fuel pin/pump upgrades and head studs. Along with all new accessories. Rough HP goal between 350-400hp.

I'm going to use the conversion parts from dieselconversion.com to keep the torqushift and use custom tuning to the Ford TCM to keep all the nice tow/haul features. I have all the parts coming to keep full functionality in the stock dash, and keep a functional cruise control. I'm going to document the swap in this thread and post final costs and reviews after completion. I also have a deadline of about a month, so this should go pretty fast...

Disclaimer: Yes I have weighed the pro's and cons of keeping the 6.0 and I know if my state starts emissions testing that with this engine I will not pass.
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6.0 owner be like: "There was that one time I made a trip without problems."
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Old 02-04-2014, 11:11 AM
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Sounds like a way cool project, but is this really the correct sub-forum for this topic?
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Old 02-04-2014, 11:14 AM
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joshjones.thewelder
Should have weighed the pros and cons of asking that question in the 6.0 forum.

Try reposting in the Engine Swap forum.

Josh
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Old 02-04-2014, 11:20 AM
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Or a Cummins site
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Old 02-04-2014, 11:28 AM
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I just figured some 6.0 owners might find it interesting...
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05' F-250 CC FX4 Lariat- 12v Cummins with DDP sticks and other goodies - 4" turbo back w/ 6" tip - 55 gal aux fuel tank hidden in the tool box w/ tank selector.
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6.0 owner be like: "There was that one time I made a trip without problems."
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Old 02-04-2014, 12:38 PM
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Quote:
Originally Posted by Kert0307 View Post
I just figured some 6.0 owners might find it interesting...
I would very much find this issue interesting.

Especially if you keep detailed and accurate notes of the costs and how the swap is performed and all that is needed to make the swap.
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Old 02-04-2014, 01:20 PM
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Old 02-04-2014, 01:54 PM
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Series of videos on a Cummins Swap


2003 F-250 CC 4x4 : Swap 7.3 to 24v 5.9 Cummins 2007 Remand


Guys Comments

All said and done... $10K- The p-pump conversion was 3K alone and I did everything myself. You could do the swap for around 5-6 but I wanted 600-700 hp and 1400ftlbs+ TQ so it cost me a little more. It was well worth it!!

City & HWY average around 13-16 loaded and 23 unloaded- Almost double the mileage all around. I remember getting ~7-8 mpg loaded with the 7.3, I could barely get 200 miles to a tank- I'm glad those days are over! Also, I hand calculate my mileage. -Brian

7.3's truly are great engines! After going thru 2 of them I decided to swap to cummins... It's just hard to beat the MPG's, reliabilty and the amount of power that a 5.9 p-pumped cummins can make. You just can't beat it! BTW: 1st 7.3 threw a rod through the block @143K, 2nd one started leaking fuel in to the coolant. Got tired of messing with them.

It only took me 2 days and a total of $10K so far... which is better than spending $62K on a new one. Anyways, you can get a dodge truck that has been wrecked and use the drivetrain from it. It'll save you a lot of $. If you go that route try to get a manual transmission with it because dodge automatic transmissions are junk. It'll cost a few grand more to get to the 5-600hp range (turbo, injectors and modify the p-pump). Make sure the engine has the p-7100 injection pump too. Good Luck!

The wiring was not too bad. The engine that I used came out of a freightliner, which uses a different ECM than what comes in dodge applications. So, since the ECM's are different the wiring is also different. Whatever you choose to go with, I don’t see it being that difficult. If you were to go ahead and install a p-pump (P7100 Fuel Injection Pump) then you don't have to worry about any wiring at all, you can make a lot more power AND p-pumps are much better than vp-44's. I plan on swapping soon

Update: The VP44 went out the other day (POS!) so a p-pump will take it place here shortly! Everything has already been ordered! It's going to get very interesting...

If you're trying to save some money buy a 12V p-pumped cummins with a dodge manual transmission (NV4500 or something similar). If you go this route you will only have to buy motor mounts ($350) and a t-case adapter (300). Reason being is that if you choose to use the 5R100 then you have to get a trans controller ($1000) wire it up and program it... which I've heard is a nightmare! Since your truck is a gasser now, you already have the right CC and throttle pedal- just go get a clutch pedal assy


Day 1: 7.3 Engine Out


Day 2: Cummins In

Day 3: 10 hours to this point

Day 4: Cummins Working
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Old 02-04-2014, 04:46 PM
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Ok, beginning 5.9 tear-down tonight. Here's what's on order or here already engine related.

Used 1991 12v 5.9 Cummins out of a D350 w/200 day warranty - $1150
Full Gasket set (felpro)- $200
Dynomite Diesel 75-100hp injectors - $600
H1 turbo rebuild kit - $85
H1 60mm comp housing w/ new wheel - $285
H1 16cm turbine housing - $195
Grade 10 upgraded head bolts - $135
New AC compressor - $250
Power steering pump - $250
water pump - $60
VE pump Fuel pin and governor spring - $155


$3,365 total into the engine so far, should be about all that goes into it as long as the bottom end checks out.
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05' F-250 CC FX4 Lariat- 12v Cummins with DDP sticks and other goodies - 4" turbo back w/ 6" tip - 55 gal aux fuel tank hidden in the tool box w/ tank selector.
Quote:
Originally Posted by Snowseeker View Post
6.0 owner be like: "There was that one time I made a trip without problems."
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Old 02-04-2014, 06:34 PM
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I just moved you over to General Diesel from 6.0L Forum for now.
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Old 02-07-2014, 03:10 PM
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I've gotten the 5.9 mostly torn down for inspection. Engine had 168k on it, still has cross hatching on the cylinder walls! Pistons are standard, so it has probably never been overhauled. Bottom end looks good, no heat discoloration on any of the main bearings or connecting rods. I'm going to pull the caps on them anyway to check just in case though.

First thing I did was pull the Dodge badge off the top of the engine, won't be needing that anymore...

Click the image to open in full size.




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Planning on pulling the 6.0 out of the truck this weekend. And my box of conversion parts is suppose to show up mid next week.
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05' F-250 CC FX4 Lariat- 12v Cummins with DDP sticks and other goodies - 4" turbo back w/ 6" tip - 55 gal aux fuel tank hidden in the tool box w/ tank selector.
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6.0 owner be like: "There was that one time I made a trip without problems."
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Old 02-07-2014, 07:51 PM
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Ill never understand why people pull brgs to inspect them, if im that far on an engine over 100k I get new ones... thats just me.
Fummings are nothing new, the 12v was an ok engine all in all as well. Best of luck hope it goes well.

Please keep in mind though dodge is the honda accord of the truck world, the smallist engine that makes the most noise
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Old 02-09-2014, 04:39 PM
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Quote:
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Please keep in mind though dodge is the honda accord of the truck world, the smallist engine that makes the most noise
Haha... Thats great. I did get a resonator/small muffler to put in my 4" exhaust for when I get it all put together cause I know from other straight piped Cummins I've seen/heard it was going to be more obnoxious than the 6.0 was. I kinda doubt the 5.9 will be louder under the hood than the 6.0 though cause 6.0 injectors aren't exactly quiet either. It might shake a little more than the 6.0 though.
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05' F-250 CC FX4 Lariat- 12v Cummins with DDP sticks and other goodies - 4" turbo back w/ 6" tip - 55 gal aux fuel tank hidden in the tool box w/ tank selector.
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Originally Posted by Snowseeker View Post
6.0 owner be like: "There was that one time I made a trip without problems."
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Old 02-10-2014, 09:09 AM
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Almost out. Tried to pull it out but the oil pan is a little deep and it's going to have to come off to pull it out.

Click the image to open in full size.
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05' F-250 CC FX4 Lariat- 12v Cummins with DDP sticks and other goodies - 4" turbo back w/ 6" tip - 55 gal aux fuel tank hidden in the tool box w/ tank selector.
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Originally Posted by Snowseeker View Post
6.0 owner be like: "There was that one time I made a trip without problems."
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Old 02-10-2014, 06:42 PM
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Nope its not your just not hooked up right they will come right out with intake and pan on
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Old 02-10-2014, 06:42 PM
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