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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

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Old 01-19-2009, 08:41 PM
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5.9 Cummins Swap

Alright, I know you here a lot about people who want to and dream of swapping a gas motor out for a 5.9 cummins in their 250 and 350s. But has anyone actually done it themselves and know things i would run into and have pics of their endevor? The receiveing truck would be a 92 f250 with a 351 and auto trans. Thanks
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Old 01-19-2009, 08:49 PM
DJdemon6696 DJdemon6696 is offline
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it has been done. allot of times there is actually a kit that you can buy for the swap..

fordcummins.com - Increase Horsepower with Ford Cummins Diesel conversion kits
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Old 01-19-2009, 09:31 PM
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I just finished swapping out the 302 in my 95 F-150 for a 3.9L cummins 4bt. I went with the 4bt for its lighter weight (half ton truck though) and better fuel economy.

http://www.ford-trucks.com/forums/81...l-f-150-a.html
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Old 01-19-2009, 09:44 PM
Tommy_Mills Tommy_Mills is offline
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If your going with the 12V it will be way easier. Less electrical! Whatever you do dont use the ford tranny (manual or auto) they wont hold up. I had a buddy do a swap, and went through 3 ZF tranny's before going to the nv4500. The cummins has way more tourque than any of the older ford tranny's can handle. Stay away from the GETRAG tranny as well. They dont have a removeable race for the rear output, its machined into the cast iron case. I am actually getting ready to do a swap with a 12v and nv4500 into an old 60' f500. got the motor and the tranny already just have to get started.
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Old 01-19-2009, 10:52 PM
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If your going with the 12V it will be way easier. Less electrical! Whatever you do dont use the ford tranny (manual or auto) they wont hold up. I had a buddy do a swap, and went through 3 ZF tranny's before going to the nv4500. The cummins has way more tourque than any of the older ford tranny's can handle. Stay away from the GETRAG tranny as well. They dont have a removeable race for the rear output, its machined into the cast iron case. I am actually getting ready to do a swap with a 12v and nv4500 into an old 60' f500. got the motor and the tranny already just have to get started.
An E4OD in good shape (ideally a built one) or a C6 (esspecially one with a gear vendors overdrive would be awesome with a Cummins) would stand up to the torque as just fine.
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Old 01-20-2009, 01:25 AM
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Although you asked for info from people who have done the swap I thought I'd chime in on what I know. I've been researching this swap for about 6 or months now... I have a real good understanding of the different ways it can be done and an idea on how I want to do mine.

The biggest problem is going to be having a realistic budget and obviously the money...lol. I've had the chance to look at two trucks locally and even drove one of them ( super nice guy I met on another site) and both had about 10k and about 200hrs into the swap. The swap and all the problems and solutions that go along with it depend on what engine and tranny you want to use and the quality of the job you want to end up with. You can use any ctd engine and tranny combo you can think of and can weld, past, glue and bolt it all together in Any fashion you want. I've looked at hundreds of picts of different swaps ( and two up close in person ) and have seen some swaps that look like the damned engine was a factory install... and I've seen a couple who if it was me I would be embarrassed to drive the truck let alone post picts of it... lol.

The other thing is what do you want to use your truck for after the swap? Is it a daily driver... sled puller... or a light 4 wheelin rig? once again the answer will lead you to kind of parts that best suit "your" swap... and give you an idea on how much work and the kinds of things your going to have to figure out.

The thing I have learned is that no two swaps are the same... every one has different parts and build quality's. From what I've read and heard people usually wish they had used the dodge trans and transfer-case just for the ease of install and the fact the starter is on the drivers side away from the exhaust down pipe, ford zf5 and 6 tranny's put the starter on the pass side. Most would say that buying motor-mounts is a wast of money as there way cheaper to fab your self if you have the skillz. take a ton of measurements!!! this swap is a real tight fit and can cause a whole bunch of problems if you dont sit the engine right (watch your fan to rad /engine to x-member clearance). The rad from a 460 or a diesel (hd cooling only) is usually the choice but do require some fab work to get the hoses to work. Some have used the dodge rad with good results. The dodge or ford intercoolers will work, just make sure they fit around the sides of the rad your going to use. The alternator is a personal decision.... stick with the ford and find a pulley and make a mount or use the dodge and figure out how to wire it into your truck. And the adapter plate of choice seems to be the de-stoked but there are others that you might want to look at too. There are a bunch of fuel related issues that come with a diesel swap into a gasser and you'll have to look into the different ways to overcome them.

There is nothing wrong with using any tranny as far as I'm concerned as long as it meets your requirements and can handle the power output of the engine your putting in... most stock 12v's have the same hp as the ford diesels and any ford diesel trans will handle a mildly modded cummins. And all of the cummins engines including the 24v's are an easy swap... dont be fooled by people who say it's too hard to swap a computer controlled cummins into your truck... they don't know what there talking about and it's easier than you think. And lastly you will not find one person who is at all unhappy with there swap... most are ridiculously happy.

here are some links that helped me:
Cummins-Conversion.com • Index page
DESTROKED: Cummins Conversions
fordcummins.com - Increase Horsepower with Ford Cummins Diesel conversion kits
Photo Gallery - Main Index - Powered by PhotoPost
ford cummins swap pictures and videos on Webshots
Cummins Conversions - Shop Talk - Tools - Fabrication - Dodge Cummins Diesel Forum
Auto World
Car-Part.com--Used Auto Parts Market
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Old 01-20-2009, 01:49 AM
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Old 01-20-2009, 06:01 PM
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two other things I should have mentioned: depending on how you do the swap and the drivetrain you use you might have to have custom drive shafts made up. And there are problems with using different tranny and transfer cases as not all of them have the speed sensor that will work with your speedo... might be a consideration on what trans you use.

thanxs preppy.....
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Old 01-20-2009, 08:06 PM
Tommy_Mills Tommy_Mills is offline
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I am going to have to disagree with using an E4OD or a C6. Although they are stout trannsmissions "I will give them that". If you turn the cummins up like most people would because it is easy (dont need to buy to many parts) you will at times ask for everything that the cummins has got, and your tranny will pay unless it can handle the torque. Of coarse this is my opinion, and I am going to personally use the nv4500. It has proven itself to stand up to the cummins under heavy loads, and lots of torque. not only that its funner to shift gears anyway.
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Old 01-20-2009, 10:09 PM
1994 F250: 351, C6 1994 F250: 351, C6 is offline
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I just think the C6 especially is as stout as any auto, but I agree that sticks are best with diesels. I have driven diesel pickups with both autos and sticks. I have also driven medium duty trucks with both sticks and autos. As far as semis go I have driven only roadrangers, both 10 speeds and mostly 13s. In my experience I have found that shifting your own gears is the best way to get the most out of a diesel's powerband.
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Old 01-20-2009, 10:10 PM
1994 F250: 351, C6 1994 F250: 351, C6 is offline
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I just think the C6 especially is as stout as any auto, but I agree that sticks are best with diesels. I have driven diesel pickups with both autos and sticks. I have also driven medium duty trucks with both sticks and autos. As far as semis go I have driven only roadrangers, both 10 speeds and mostly 13s. In my experience I have found that shifting your own gears is the best way to get the most out of a diesel's powerband. For ease of use I would probably say the nv4500 is the most logical choice.
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Old 01-21-2009, 01:05 AM
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I'd have to agree that the c6 probably isn't the best tranny to use and to tell you the truth I dont even think I've seen a post or a pict of one with a cummins in front of it... I dont know too much about tranny's but I do know that the gear ratio is something to consider when swapping a cummins. The cummins is a low rpm diesel and I've read that taller gears are best. Even with the governor spring kit installed people have said that having a cummins rev at 2000 rpm to stay at hwy speeds does no good for fuel economy. I wonder if all tranny have a similar final out put ratio?
Personally I would love to have a nv4500 under my truck but the cost and difficulty of finding one leads me to keep my zf5... and hopefully upgrade to a zf6 when I can afford it. But I have modest expectations as far as my hp goals are and really only want to see 350 ish... just need to be a bit more than my buddy and his new harley davidson F350...
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Old 01-21-2009, 07:43 AM
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Originally Posted by Ford4x4-JD70AB View Post
I just finished swapping out the 302 in my 95 F-150 for a 3.9L cummins 4bt. I went with the 4bt for its lighter weight (half ton truck though) and better fuel economy.

http://www.ford-trucks.com/forums/81...l-f-150-a.html
Do you have any videos?

This question goes to ANYONE who put a Cummins in a Ford.

So awesome.
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Old 01-21-2009, 10:37 AM
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I dont have any videos of the engine in the truck yet...but there will certainly be several to come. These single digit temperatures have been discouraging.
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Old 01-21-2009, 11:02 AM
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I dont have any videos of the engine in the truck yet...but there will certainly be several to come. These single digit temperatures have been discouraging.
Please don't forget me when you get the time to take a video. I'd like to see vids of the process as well.

Been in the mid 60's and high 70's here, bud. I wish I could send you some of our heat. I love the cold.
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Old 01-21-2009, 11:02 AM
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