Does anyone have a ballpark estimate to do a 12v cummins swap on a 77 highboy with a 460 in it? I have been searching the forums and so far from what I can see its about $5-6k? Also can you help me with the list of materials? So far I'm thinking I'll need:

Engine / transmission - $1500?
Machine shop work (engine rebuild) - $1500?
Engine rebuild kit - $1000?
14 bolt rear axle - $300?
axle rebuild - $400?
Cut and balanced mid shaft - $150?
Intercooler - ?
front brake disk conversion - ?
Dana 60 front - ?

 

Radiator? Clutch linkage? Will you need higher gears? Will you need to do something with the steering at the same time?

 

I was planning on sticking with the stock radiator and fan that is in it. Do you think I will need to do a power steering conversion?

 

5K doesnt seem out of the ball park to me. When I did mine, I spent about a grand on adapters and junk like that, the starter and what not; 1700 on the engine and not too much more on steel and stuff to build engine mounts. I dont think I can pin down what other major expenses there were, but I didnt buy a new set of axles and suspension. Or radiator. I didnt rebuild or have machine work done. And I used the stock intercooler...which was an air-water unit.

I used the stock C-6, although I'll be putting a ZF5 into it when I can get some work space with cement under it.

I guess I did mine the easy way, cause it didnt seem like I put near as much work into it as some other people have and yet...I still have a great time driving it around.

 

I plan on making this a daily driver so I'm going to try and rebuild / machine / reinforce as much as possible. Thank you for the info, helps in trying to determine what is really necessary to do the conversion and what is not. Did you have to change your brakes at all? Are you still using the stock rear? I've heard they can tear out pretty quickly with the 5.9.

 

im right in the middle of a cummins swap. the cost just seems like it keeps piling up more then i thought it would. but i do think it was the right choice and i wouldnt change anything. ill try to make a list of all my expenses so far

engine/allison at-545 trans - 1400. i got a deal on that one from a friend
engine parts/gaskets for rebuild - about 700
also rebuild the trans just to be safe - 250
put a D70 in the rear - around 500 including all new gaskets and bearings
radiator - around 300
and ill add another 500 for misc. parts and for some things i probably forgot.
and i still need driveshafts, all new u joints, gauges, intercooler, and probably a few more things that ill think of down the road.

 

$$$$$5K should do it, In my neck of the woods, 5.9s are $2000 and I think I am going to have one to sell, but apparently other areas they are less. I would go big on the radiator, front 60, and run 373>354 gears, I am not sure that the cost is that much, it seems to be more in attaining the engine and transmission.

 

$5,000 or there abouts. I broke it down in my build thread but off memory it looks something like this.

Engine and trans $1,400
Divorced 205 $250
Drive lines $1,100
Radiator $200 (?)
Batteries $200
Battery cables $140
Hydroboost conversion $500 (you need this)
Etc.
Etc.

Add another $3600 for the Dana 60 and cross over steering

https://www.ford-trucks.com/forums/1...l#post11218449

 

Mine lasted a few months before this.

http://s742.photobucket.com/user/Fordworth/media/D60%20Destruction/2012-02-06_19-11-04_608.jpg.html?sort=3&o=2

 

Rrrrrrrrr, I can't get photosucket to work from my phone. Anyway a D60 probably won't last long. Especially with a manual trans and a heavy right foot. The stock radiator does fine but you have to get creative with the plumbing. I had the spouts switched side to side. I spent about $3000 on my swap but I found some pretty good deals, like a low mileage engine for $700.

 

Here is the picture he linked

 

I'm still using the stock rear and front ends with no problems. It's been a daily driver 'till the last few weeks when some equipment was parked behind it, blocking it in...possibly forever...

Anyhow, in it's down time, it's getting AC added and a new fuel sending unit...

At any rate, even for a daily driver, rebuilding that stuff is overkill unless there's a reason for it, but you dont have to have a reason to do things while building a project.

What charge air cooler are you going to use? A stock Dodge unit, industrial or an aftermarket unit?

You planning on fiddling with the pump? Have you checked out www.4btswaps.com?

 

Thanks for the link. I did find a ton of useful information last night at Home | Diesel Conversion Specialists

From what I have read I think I am going to use a newer 31" superduty intercooler. As far as the pump, I plan on tuning it for performance as well as the turbo. If I have enough money left over I will just buy performance parts but for now the goal is to get the engine fitted and in and then I can always go from there. I haven't made a decision on the trans yet. I do a lot of mountain driving here in Colorado so I don't think I want to stick with the 460 C6 I have now. I would like auto so I'm thinking a 5R110?

 

You are probably better off sticking with a tranny already built for a cummins and beefing it up a tad. ATS makes some really nice component that make the cummins autos damn near bulletproof. You are probably going to spend more money adapting that 5r110 to the cummins than the cost of beefing up a tranny meant for it already.

Your 6k estimate is pushing it, if you going to be running an auto with any kind of performance upgrades. Think about the engine internals before anything else. The basic stuff is going to cost you a grand easy. IE a cam, arp head and mains studs, o ringing etc. It's all the little stuff that adds up with these engines. I am into my cummins almost half your estamate for machine work, plus having a cam ground and the head o ringed. The cost does not include assembly which I am doing myself. When I get the engine back ill post a better break down on my thread.

 

im just gona say ALOT lol