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Unless you are an experienced fabricator and mechanic and you have lots of time or money on your hands, you should find someone who has already done this swap before and documented the process. The question you should be asking, "Has anyone done this swap?" Good luck!
The engine swap wouldnt be the issue, but fabricating all the mounts, drivetrain, and electrical is going to be the costly and time consuming part! None of the driveshafts mate up withe the older powertrain, so fabrication is a must do. Electrical will be the biggest nightmare, as not only will you have to change all the wiring under the hood, and a lot of chassis, but all of it under the dash, including fabbing up older gauges to fit the newer body style.
I would include all of those things you mentioned as part of "The Swap"...hence my suggestion to find someone who's already done it.
Exactly! I was ellaborating a little more from my experience! LOL! I have done a full tilt swap (check my link in my sig), and those were just some of the things I had to deal with when I did!
Some people might hate me for suggesting this but I think if you where going to do a swap you would be better severed to due a Cummins swap. They have numerous kits on the market that include every thing complete including what you will need to make the trans work correctly and the gauge cluster in the cab. If you build a kit yourself a lot of times the parts will not be readily aviable and you will have a hard time building or finding them in the event of a faliure. Most cummins swap kits use No fabrication necessary parts that can be found on the shelf at common part stores. Last but not least in the end you will have a motor that will last as long as the truck. I am personaly a big fan of the 7.3 powerstroke and i am NOT saying the 7.3 would not last as long as a 5.9 cummins, but IMO the 5.9 cummins is just as reliable power plant but offers more aviable options for a re-power swap.
Had the exact same thing happen to our 6.4... Ended up getting a used 6.4 and having a shop put it in. Also needed A couple new parts including a radiator. Around $15k in engine, parts, labor.
I've heard a bit about the Cummins swaps, and it seems a lot easier than swapping a 7.3 in even though the 7.3s are great. Don't know where you're located, but I know of a shop here in VA that specializes in these various swaps and do cummins swaps in F-series.