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2004 - 2008 F150 2004, 2005, 2006, 2007 and 2008 Ford F150's with 5.4 V8, 4.6 V8 or 4.2 V6 engine
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Old 07-25-2014, 12:23 PM
Bmarr1994 Bmarr1994 is offline
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Big Plans

Alright y'all, I bought my first f150 a little over a year ago, a 2006 xlt extended cab 4x4 with a little over 125k miles. Was in the market for a diesel, but for some reason this just caught my eye.

Well needless to say, my experience with the truck hasn't been the greatest. I swear it is possessed.

First I broke a plug off in the head while doing a tune up, went and bought the 200 dollar tool to remove broken plugs, it didn't work. So at this point I figure the only people that would know how is a ford dealer. Take it to a ford dealer, they tell me my head is shot. Wonderful.

Send it in to a local mechanic for a new head to be installed, I get the truck back several weeks later, the guy tells me my truck is possessed, everything that could go wrong went wrong. But it runs good now. So I go and drive it around for a while, seems normal, so I start to daily drive it again. 4 days later, I find out the valves are fried when my engine locks up and is about 3 quarts low on oil. (With no leaks) 4 days previous I did an oil change and it was full.

Well, it's been sitting since that day, around a month and a half ago. I've been pondering what to do with it and I think I came up with a plan.

I'm thinking I'm going to 4bt cummins swap the truck, with a zf5 out of a mid 90s powerstroke for the trans. I've been told and read places that my transfer case will bolt to a zf5, which is important to me, don't wanna spend more money on the tcase. I will be removing the PCM due to the fact that I will not need one for a diesel. After that I am kinda lost on what to do, I know I will need a whole clutch assembly, but what else?

Any help is appreciated
Thanks
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Old 07-25-2014, 04:59 PM
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danorules danorules is offline
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Springs! You are gonna need more suspension under that diesel. Also drive shafts, fuel tank and pump and sending unit, exhaust, fan shroud, radiator, intercooler ( if turbo), engine and tranny mounts, and all sorts of little things
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Old 07-25-2014, 08:20 PM
Bmarr1994 Bmarr1994 is offline
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Why would I need drive shafts? I'm keeping the same tcase so the drive shafts are going in just the same. I will need springs, but not super heavy duty ones, as a 4bt only weighs about 75-100 lbs more than my 5.4. Don't need an intercooler, 4bt is a non intercooler turbo. Also won't need fan shrouds because of using electric fans
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Old 07-26-2014, 06:55 PM
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You will need shafts if the transfer case doesn't end up in the same location. I assume the total length measurements are going to be different with the set up you are thinking about.that will then require longer/ shorter shafts
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Old 07-27-2014, 07:21 PM
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How much do you plan on modifying the 4bt? I have heard they can make good power but isn't stock form around 150 hp and 300 ft-lb of torque? Also gear ratios would be important. A diesel is not gonna like being around 3k rpm all the time but will have the torque at lower rpm that a gasser will not.
Can you fabricate custom mounts for the A/C compressor and power steering pump? Will the computer controlled alternator work with just a reference voltage or are you just going to replace it with a simple 2 wire unit?
I would highly recommend putting a salvage yard engine in the 06 selling it and putting the powertrain you're planning in an older truck. 73-79 Fseries maybe or whatever make/age range you like. I'm sure you could find tons of info on a swap like that. It's your truck, labor and money but if you're going to go full custom set up why not have a classic body style to go with it?
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