Sorry to hear emissions regs killed your Cummins swap.
It would have been a SWEET ride.
Having never owned a gas Super Duty (last gas trucks I had where FE and 460 powered) there's not much I can help you with, but good luck on your build.
I'm still following to see the finished product.

 

Well guys, Christmas cleaning is starting...well garage cleaning anyway. I have been stuffing everything in my garage to the point where i cant open the door from the house and walk into it anymore. This weekend i am going to pull the charger out for the winter as much as it kills me to do that and make room to work again. Next weekend the wife is going away for a family girls trip so i have the whole weekend to myself to get this motor cleaned up and ready to go back in!

Quick question for you guys though, since i cut my exhaust flange off because i was an idiot and thought i wont need it, i now need a new y pipe but i was going to just go completely custom. Is there anything critical i need to know about the placement of the O2 sensors etc if i get a custom system at the shop near me? trying to plan out and budget for the stuff i broke that i now need again.

 

I think this is the perfect opportunity to get a true dual exhaust system. Do headers, dual cats, H-pipe, and dual mufflers. You have a V8, make it sound like it

 

Agreed, I'm looking into that now! I am trying to see if there is a bolt in system i can use or if i am going to have to go to the local shop and get something bent up which will likely be more expensive for the shops around here...kicking myself for cutting stuff when I shouldn't have

Good news is I cleaned up the garage this weekend so i now have all the room in the world to get the motor out form the back workshop and into the light were i can finally start working on it. Hoping ot get it back into the garage this week and get her washed down and all the accessories removed that i want to replace while its out.

 

I'm helping a buddy 4bt swap his Cherokee, and something that's making the exhaust easy to work with is V-bands and clamps. If you're going to go through the effort of making a badass exhaust you might as well make it easy to work on because it will more then likely be in the way.

Also if you're going to be using it off road at all I would recommend flex joints in there somewhere. I have to redo my manifolds after my last off road trip because it snapped 3 bolts.

truck is looking really good. Bummerr to hear about emissions. NJ finally did something nice and now any vehicles under over 8500 and under 10k don't have to be inspected anymore. So a 12v or 24v swap might be in my future since it's being ever so slowly being converted to an off road rig.

 

That's a good point, ill have to start looking into that, is there an ideal placement for a flex joint?

It is a bummer about the swap however i am going to hold on to the motor and trans because i feel like i will eventually use them. I have actually given some serious thought to dropping git in the charger... its the only vehicle i own that i can actually do it to in MA. and with my budget now that im a home owner lol its cheaper than getting the current power train up to snuff to be drivable on the streets. I know some people will hate on me for it but I'm still not sure and i could easily get a manual to fit the cummins and it will technically be all mopar/dodge

Anyone have thoughts on swapping in the allison in place of the 4r100 with the 5.4? not going to do it but if i go with the above and put the cummins in the charger then i will have an allison 1000 5 spd sitting around and i figured once the 4r100 goes...well its just sitting there and i can get the stand alone harness for it. Adapter plate and flex plate would be an issue but aside from that...idk just spit balling thoughts really. My primary focus is getting the F250 back together and running by this summer Once that's done the charger goes in the garage and starts its rebuild.

 

I was going to look into putting them before and after the y pipe seems like that might be a contributing factor to the twist granted I'm also debating on adding a turbo to mine so that may change .

As far as the challenger the only problem I might see with the cummins/Allison combo is the weight and the reinforcement you'd need to do to stop it from twisting. If you have no plans to restore it then I say go for it. If you want to actually restore it, I'd say no only because you'd end up having to modify too much .

And as far as the Allison I think you can add power to the 4r100 for less then 4thhe adapter and controller. I installed the factory tech valve body over the summer and the shifts are much more aggressive and positive 1-2, and 2-3 are noticeable at almost all throttle positions.

 

I have a Transgo shift kit and .427 line modulator valve for the 4r100 that I bought a while ago. I sold my 2000 v10 before I was able to put it in. If you're interested, shoot me a PM and we can workout something to get it to you.

 

It's been quite a while. What's going on?

 

I'm late but I wanna add some my I put on the hear swap. I finally did a 4" loft with 35's on my truck (I had 4.30 already) first trip around the neighborhood and I absolutely hated it! The truck felt.like it did with stock tires and the 3.73 gears Ford decided was a good match for a f250 with 5.4 motor. Getting on the highway i had my foot buried into it and the truck just creep up to 70mph like a turtle when it use to FLY for a truck of this size. Well in short the lift and tires lasted one week before i went back to leveled and 285/75r16....

 

For 35" tire you need something in the range of 4.88 - 5.13 gears
Do the gear calculations but you probably find 35's with the 4.30 gears probably equaled 3.55's or 3.31's with stock tires

 

Actually on a 2004 with the 5.4 a 4.30 gear got me back to the stock 265/75r16/3.73 combo. I instantly remembered HOW BAD I HATED THE TRUCK THAT FIRST YEAR with them ridiculous 3.73 gears and how weak the 5.4 felt when I installed the 35's a few weeks back. And like I said the whole setup lasted less than two weeks before I took it all off and went back to how I liked the truck

 

I'm running 3.73's with a 32" tire and really like that setup, but then I've got a 12v Cummins setting up front, it doesn't know what the word weak means.

 

Hey guys, I'm still around been really busy with work and paying student loans/home ownership doesn't exactly help with my parts budget lol. I looked up the gears a while back and 4.88 got me to i think 3.5ish when calculated out like you said Destroked, I will likely run 4.88's but not right away, i drove the truck with the 3.73 gears to NH and back which was about 40 miles a day on the highway and it was tolerable. Now that I dont need it for long trips and highway runs and its going to be for more around the house and around town for my wife's business she's starting I will probably hold off to save some cash and finish up everything else first.

By the way, i have not updated you guys, I got rid of the Expedition unfortunately it just started to fall apart, the calipers kept seizing then my brake lines were all failing and the rockers just dropped out from underneath one day without warning (internal rusting) it was eating into my budget for a long time just trying to keep it running so I was not able to buy parts for anything else. But I got a 2016 Dodge Charger R/T and i absolutely love it! plus it doesn't break every few weeks lol. But after doing that and being able to save some cash again I got permission to start buying what i need to put the truck back together now lol.

If i dont get stuck at work today i bought more POR15 to finish painting the engine bay so that may happen tonight and I am going to have my wife upholster the new headboard to get it in there and replace my old one that I did a while back. Also looking of opinions on using stock lines vs AN lines for the PS pump, fuel, and everything else because i cut all my rubber lines when pulling the engine like an idiot and I am figuring now that i can get creative and use the different color braided lines for different fluid types.

 

Any updates? We haven't heard from you in while.