1996 E-SuperDuty Bus
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Tuned
Joined: Apr 2003
Posts: 295
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From: Kountze, Texas
Removed the floor covering and installed 2 thicknesses of foil covered insulation and re-installed. Relined the engine cover with Thermotec heat barrier. Removed door panels and covered doors with sound control stuff and covered the rear floor with 3/4" thick rubber horse stall mats from Tractor Supply. Big difference in noise and heat control! Also learned something about cruise control modules. Replaced mine with one from a Mustang 3.8 V6. Works fine. Replaced the "Circuit board" portion with the original one from the bus and can't tell the difference at all. Looks like the Servo sections are all the same on the Fords, but there could be minor differences in the circuit board sections. Easy swap with 4 screws and plug in.
Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
Ford got tricky with the various years CC modules, occasionally changing the internal wiring harness connections, quite possibly to thwart interchangeability---forced to buy the specific year/make/model part. At $450 MSRP one simple almost cost free change like that and they have what they think is a captive market.
All your sound control and insulation certainly has to make a huge difference---more pleasurable driving I'm sure. Those horse stall mats have to be one of the best cheap floor coverings out there. One huge benefit is their durability--last a life time with just people traffic on 'em!
All your sound control and insulation certainly has to make a huge difference---more pleasurable driving I'm sure. Those horse stall mats have to be one of the best cheap floor coverings out there. One huge benefit is their durability--last a life time with just people traffic on 'em!
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Tuned
Joined: Apr 2003
Posts: 295
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From: Kountze, Texas
Now reworking the A/C systems. Removed the 2nd compressor from the rear system and tied it into the front factory A/C lines. I removed the radiator mounted condenser and run everything through the huge skirt mounted condenser setup. Everything seems to work pretty good. Now I am in the process of reworking the heater lines. I bought the correct thermostat housing and it has a 5/8" tube coming off the top in addition to the common 1 1/2" hose. What does that hook to? Anyone have a diagram or picture of 460 water hose setup?
Cargo Master
Joined: Mar 2007
Posts: 2,935
Likes: 34
From: Arcadia, Fla
Now reworking the A/C systems. Removed the 2nd compressor from the rear system and tied it into the front factory A/C lines. I removed the radiator mounted condenser and run everything through the huge skirt mounted condenser setup. Everything seems to work pretty good.
I have a 96 F350 shuttle bus(short bus) that I am converting into a weekender RV. Please tell me more on how you hooked the rear AC system into the chassis AC system. The rear AC compressor on my bus is rattling and probly will lock up soon. Also I am tired of the drive belt wearing out as its driving 2 AC compressors and a 200amp alternator!
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Tuned
Joined: Apr 2003
Posts: 295
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From: Kountze, Texas
Eddie, I still have a bug to work out as the in-dash air isn't as cold as it should be. It's close, but not quite where it should be. I may have to experiment with different orifice tubes.
Does your bus have the extra hose connections on the thermostat housing? If so, I am needing to know where the hoses go.
Does your bus have the extra hose connections on the thermostat housing? If so, I am needing to know where the hoses go.
Cargo Master
Joined: Mar 2007
Posts: 2,935
Likes: 34
From: Arcadia, Fla
I was wondering about the FS10 factory compressor being able to handle both units.
I'll check the t-stat housing and see what my bus has. I recall the rear heater lines are t-ed into the cab heater hoses.
I'll check the t-stat housing and see what my bus has. I recall the rear heater lines are t-ed into the cab heater hoses.
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Tuned
Joined: Apr 2003
Posts: 295
Likes: 0
From: Kountze, Texas
Well its been quite a while since I updated this thread. Since then, I tinted all the windows much darker, bought 4 new Firestones for the rear, and finished and insulated the inside of the rear door.
Just returned from our 2,000+ mile annual trip to Colorado with no problems. Solid 7.75 mpg. Still need to do a little work to the A/C system (I think there is a small leak) Now I need to decide if now is the right time to replace the 460 engine with the Cummins diesel I have in my garage.
Just returned from our 2,000+ mile annual trip to Colorado with no problems. Solid 7.75 mpg. Still need to do a little work to the A/C system (I think there is a small leak) Now I need to decide if now is the right time to replace the 460 engine with the Cummins diesel I have in my garage.
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Tuned
Joined: Apr 2003
Posts: 295
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From: Kountze, Texas
I still haven't started the Cummins/5R110 conversion yet as I am waiting for cooler weather. Been working on the A/C system. Replaced O-Rings, Drier, Sightglass, Accumulator, and orifice tube. Then evacuated the systom for 5 1/2 hours, checked for leaks for 2 hours and re-charged. It now blows pretty cold!! I still think I need a little more compressor capacity, so I am going with a larger size compressor when I do the Cummins swap, but it's pretty darn good for now. Yesterday I took all of the family on a little 200+ mile trip in the bus to see how all of my little changes worked out.
Let me start by saying that the rear gear change from 4.63 to a 3.73 ratio is the best thing I have done! Yes, it is a very little down on power, but not enough to really matter. Fuel mileage at 65mph went from about 8 to a little over 10mpg (25% improvement!!!!) Also the engine is a bit quieter turning the slower rpms. Also the A/C works well. All in all a good day with good results. I'm liking this bus more and more!!!!
Let me start by saying that the rear gear change from 4.63 to a 3.73 ratio is the best thing I have done! Yes, it is a very little down on power, but not enough to really matter. Fuel mileage at 65mph went from about 8 to a little over 10mpg (25% improvement!!!!) Also the engine is a bit quieter turning the slower rpms. Also the A/C works well. All in all a good day with good results. I'm liking this bus more and more!!!!
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Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
Good to hear you're still making progress and improvements on your hauler. 
I'm guessing that Cobra rests comfortably in its nest right?
Kudos and a huge thumbs up for the A/C work, especially pulling the vacuum for an extended time---that alone will make a world of difference. With all you've done I'd bet your leaving air temps at the outlets would be right at 38* or so? That's enough to require sweaters even on the hottest days. Women hate it, men think its comfortable.........
I'll PM you a link to another E-Series owner who is doing his own Cummins swap---its pretty amazing if only in its scope of his work.
I'm guessing that Cobra rests comfortably in its nest right? Kudos and a huge thumbs up for the A/C work, especially pulling the vacuum for an extended time---that alone will make a world of difference. With all you've done I'd bet your leaving air temps at the outlets would be right at 38* or so? That's enough to require sweaters even on the hottest days. Women hate it, men think its comfortable.........
I'll PM you a link to another E-Series owner who is doing his own Cummins swap---its pretty amazing if only in its scope of his work.
Fleet Owner
Joined: Aug 2010
Posts: 21,253
Likes: 1,656
From: Reynoldsburg, Ohio
Yeah---with two evaporators being fed at the same time -24* below ambient might be max. The upside is dehumidifying might still be effective which can be almost as comfortable as just low temps in the cabin or rear area.
Cargo Master
Joined: Mar 2007
Posts: 2,935
Likes: 34
From: Arcadia, Fla
Good to hear things are working out. I have started full conversion on my bus, got the toilet,black water tank(had to make that up),fresh water tank and small kitchenet installed. I came across a very nice power foldup bed from a conversion van from the junk yard for just $40!!! Still have not messed with the AC system yet.
What's the pressure reading on high and low sides? As you removed the front condenser, you may not have enough condenser to rid the heat.
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Tuned
Joined: Apr 2003
Posts: 295
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From: Kountze, Texas
According to the Trans/Air guru, my 3-fan condenser unit should be plenty big for both systems. The Ford FS10 compressor is marginal at its peak and I think mine is probably a little on the weak side. I have a TM-21 size compressor for the engine swap. It has about 30-35% more capacity than the FS10.
Good luck with your project. It sounds like it will be pretty cool!
Good luck with your project. It sounds like it will be pretty cool!
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