Alright y'all, I bought my first f150 a little over a year ago, a 2006 xlt extended cab 4x4 with a little over 125k miles. Was in the market for a diesel, but for some reason this just caught my eye.

Well needless to say, my experience with the truck hasn't been the greatest. I swear it is possessed.

First I broke a plug off in the head while doing a tune up, went and bought the 200 dollar tool to remove broken plugs, it didn't work. So at this point I figure the only people that would know how is a ford dealer. Take it to a ford dealer, they tell me my head is shot. Wonderful.

Send it in to a local mechanic for a new head to be installed, I get the truck back several weeks later, the guy tells me my truck is possessed, everything that could go wrong went wrong. But it runs good now. So I go and drive it around for a while, seems normal, so I start to daily drive it again. 4 days later, I find out the valves are fried when my engine locks up and is about 3 quarts low on oil. (With no leaks) 4 days previous I did an oil change and it was full.

Well, it's been sitting since that day, around a month and a half ago. I've been pondering what to do with it and I think I came up with a plan.

I'm thinking I'm going to 4bt cummins swap the truck, with a zf5 out of a mid 90s powerstroke for the trans. I've been told and read places that my transfer case will bolt to a zf5, which is important to me, don't wanna spend more money on the tcase. I will be removing the PCM due to the fact that I will not need one for a diesel. After that I am kinda lost on what to do, I know I will need a whole clutch assembly, but what else?

Any help is appreciated
Thanks

 

Springs! You are gonna need more suspension under that diesel. Also drive shafts, fuel tank and pump and sending unit, exhaust, fan shroud, radiator, intercooler ( if turbo), engine and tranny mounts, and all sorts of little things

 

Why would I need drive shafts? I'm keeping the same tcase so the drive shafts are going in just the same. I will need springs, but not super heavy duty ones, as a 4bt only weighs about 75-100 lbs more than my 5.4. Don't need an intercooler, 4bt is a non intercooler turbo. Also won't need fan shrouds because of using electric fans

 

You will need shafts if the transfer case doesn't end up in the same location. I assume the total length measurements are going to be different with the set up you are thinking about.that will then require longer/ shorter shafts

 

How much do you plan on modifying the 4bt? I have heard they can make good power but isn't stock form around 150 hp and 300 ft-lb of torque? Also gear ratios would be important. A diesel is not gonna like being around 3k rpm all the time but will have the torque at lower rpm that a gasser will not.
Can you fabricate custom mounts for the A/C compressor and power steering pump? Will the computer controlled alternator work with just a reference voltage or are you just going to replace it with a simple 2 wire unit?
I would highly recommend putting a salvage yard engine in the 06 selling it and putting the powertrain you're planning in an older truck. 73-79 Fseries maybe or whatever make/age range you like. I'm sure you could find tons of info on a swap like that. It's your truck, labor and money but if you're going to go full custom set up why not have a classic body style to go with it?