@superdutyscaler as far as your gauges go you could swap out your cluster for a diesel cluster that way you would have the correct tach, and you may consider using the 47rh trans behind the cummins, you could buy a 47rh, and have someone build it for you cheaper than buying the adapter plate, 6.0 starter, and trans controller for your 4r100, and you could still use your same transfer case, just swap the input shaft to match the 47rh output. just my $0.02 but if you want to swap, and stay with the auto trans, this would prob be the best bang for your buck.

 

Did you try a local transmission shop for the tool you need? I'd be more inclined to think that they would have it versus a dealer.

 

always wanted to do exactly this in my 5.4 regular cab. real sweet.

 

yeah i checked with all of my local transmission shops, and no one had the tool, they all said the same thing " we dont have the tool, but bring it in and we will figure something out for ya" which i translated " bring it in, and we will use a hammer and punch to tighten it cave man style" lol. so i will order the tool and just do it myself, as they say "if you want it done rite......" i have made a little more progress though I put the front end of the truck back together, so she looks liike a truck again, and also put the bell housing on, so it is ready for the trans as soon as i get it complete.

 

Nice build thread! You the man tearing down all the drivetrain to modify.

How old is the Boxer in the tub?? My buddy Taz was 70lbs win he passed at 11yrs..

Cant wait for the video of startup.

 

Holy hell batman... How did I miss this one!!! This is an awesome swap! I don't care who you are it's hard to argue anything bad about the ole 12 valve (dowl pin excluded). I bought a cummins not too long ago but mine came wrapped in a metal dodge crate

 

looks really nice in the engine bay allot more room.

 

Very cool!! My 2004 F250 has almost 200k miles on the original 5.4L, this is the same swap I am considering aswell. I love the idea of a truck that is completely mechanical!

Are you able to keep the transfer case in the stock location (So you can use the stock drive-shafts)?

When you were assembling the transmission, what is the purpose of that KD tools gauge on the top?

 

Thanks petrokiller, i dont know about the dog i barrowed the pic from someone else lol

 

The kd tool gauge is a dial indicator, i was using it to check the end play on the main, and counter shafts and shimming them for the correct tolerances, and with the transfer case i don't know yet if i will have to have my drive shafts modified until i get it re-installed, but everything that i have read said that if you use the electric fans for the radiator you can slid the engine forward and use the factory drive shaft, but if you use mechanical fan you have to slid everything back to clear the radiator and you have to shorten the rear shaft, but the front shaft will slip enough to fit, that being said, i am using the mechanical fan, but my truck is also lifted so hopefully i wont have to modify the shaft, fingers crossed.

 

My god...theres no rust! if i was to take my engine out it would look like...idk but rusty lol. very nice, how do you plan to keep the dash from lighting up like a Christmas tree? I want to do this to my 04 but i have to deal with the whole if the OBDII says its not the original engine then it fails inspection bs in Mass... very nice swap though i love it!

 

Well i finally broke down and bought the tool and torqued the 5th gear nut, with lots of red locktight, and got my transmission completely reassembled, so i will post an update with pictures soon, should have the drive train in shortly.

 

Finally got my transmission in now just waiting for my radiator fan to get here so i can figure out the placement front to back, and punch the hole in the floor for the shifter, then on to the t-case.

 

Also if anyone has done the same or similar swap on there truck, i would love to see how you mounted the nv4500 to the cross member, i'm still contemplating that part, i know the ford mount wont work because it is way too tall, just not sure on what mount to use, or if modifying the cross member is the answer.

 

ok guys, here is the latest progress, i was able to make my measurements and drill the hole in the floor for the shifter, and raised the trans up into position, i also figured out that my tail housing is slightly different from the diesel version, the mount location on the gas version (that i have) is a lot lower than the diesel version (that i need) and with the trans jacked all the way up against the floor it still will not clear the cross member, so i have ordered the diesel version cast iron replacement, also working on figuring out the wiring and hoses, but that is the easy part. ill keep yall updated as i get it done, it is really slow going at this point but im hoping once i get the drive train done, the rest will come together quickly.