91 PSD Swap Help

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Jun 30, 2013 | 07:58 PM

91 Dixty

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91 PSD Swap Help

Hi i am new to ford truck forum, anyway i have a 1991 f250 with a dana 60 front with f350 springs and 315 duratracs, its a 302 5 speed. I recently bought a 1994.5 powerstroke with the intentions of putting it into my 91

, i guess my questions are has anyone everdone this before? does anyone know what i will all need, i have the whole truck if i need anything out of it. I already pulled the engine tranny and t-case. Also when i have the engine out is there anything i should replace? which gaskets and seals and seals normally go out on these 7.3s? any help would be appreciated

Jun 30, 2013 | 08:05 PM

Sapphire Blue_95

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From: Dawsonville, Georgia

Your going to need a diesel transmission, engine mounts, different gas tank(s) in addition to different fuel lines. Just to start off with. There was a topic about this where someone wanted to replace their gasser with a diesel, just a couple days ago. Try looking it up, it listed everything needed.......but in all reality, you would be SO much better off with just finding a diesel truck with everything there you need to do the swap.

Jun 30, 2013 | 08:09 PM

Diesel_Brad

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Joined: May 2009

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From: Gilbert, PA

COMPLETE harness(chassis and Cab) the whole dash board(they dont just bolt in either), Steering column, pedal assem, engine perches, diesel rad support and radiator(87-91 is one style and 92-97 is another), Complete fuel lines, tanks, sending units,diesel trans, you can use either t-case

It is going to be a TON of work. What is wrong with the 94.5?

Jul 2, 2013 | 04:36 PM

donniezyea

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From: Saukville WI

Guys he has a exceptionally CLEAN and I mean CLEAN 91 with a baby 302 and wants to swap in his 94.5s 7.3 that is a complete rust bucket........ While the motors out (7.3) what are the common things to replace while its on the stand for preventive maintenance. Diesel_Brad you should have the knowledge for something like this or maybe a link to a previous swap on here would be great...

Thanks just trying to help friend! good luck 91 dixty

Jul 2, 2013 | 05:13 PM

Diesel_Brad

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From: Gilbert, PA

I did chime in on what needs to be changed. Basically EVERYTHING

Jul 2, 2013 | 08:48 PM

91 Dixty

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So what can u tell me about what seals and gaskets as sensors normally go bad? And this used to be donniezyeas old truck

Jul 3, 2013 | 04:13 AM

Diesel_Brad

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From: Gilbert, PA

Quote:

Originally Posted by 91 Dixty

So what can u tell me about what seals and gaskets as sensors normally go bad? And this used to be donniezyeas old truck

nothing in the sensor department that would be worth while while the engine is out.

The manifold bolts, up pipes, up pipe donuts, turbo pedistal o-rings and oil pan are the only things I would bother with while the engine is out. Everything else is accessible with the engine in