Cummins Swap Questions
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Cross-Country
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Cummins Swap Questions
I'm looking for an Excursion to swap a 12V Cummins into and I've found what looks to be a good candidate in a 2005 Ex, but it's a 5.4L V8, not a 6.8L V10. From what I've read, most Super Duty/Cummins swaps seem to start with a V10 truck so I'm wondering if this choice is going to cause me trouble.
One thing I know is that the 5.4L trucks come with 4.10 diffs while most V10s come with 3.73 diffs which would be better for a diesel. Would the higher gear ratio be a problem for the Cummins, especially when towing (which I do a lot of)? The engine I'd put in would be a 230HP/600ft-lb setup. Are the front and rear springs the same in the 5.4L V8 vs the V10?
Any other differences that would cause me trouble with this swap? I think I read that the V10 radiator is the same as used with the Powerstroke diesels and works fine with a Cummins, but not sure about the 5.4L.
Could anyone also confirm that all gasser Excursions 2000-2005 came with the 4R100 trans?
One thing I know is that the 5.4L trucks come with 4.10 diffs while most V10s come with 3.73 diffs which would be better for a diesel. Would the higher gear ratio be a problem for the Cummins, especially when towing (which I do a lot of)? The engine I'd put in would be a 230HP/600ft-lb setup. Are the front and rear springs the same in the 5.4L V8 vs the V10?
Any other differences that would cause me trouble with this swap? I think I read that the V10 radiator is the same as used with the Powerstroke diesels and works fine with a Cummins, but not sure about the 5.4L.
Could anyone also confirm that all gasser Excursions 2000-2005 came with the 4R100 trans?
Cargo Master
Joined: Dec 2015
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From: Harned, Ky
Most use the v10 chassis because of poor fuel mileage or they picked it up cheap.
4.10 are as low as you'd want with a Cummins, it will tow well but won't like interstate speeds unless your running 35" or taller tires.
You'll need the larger radiator and different front springs to support the added weight.
Not sure about the trans question but I think it would be questionable weather the 5.4's trans could handle the torque of the 5.9.
My Fummins is a manual trans so I usually stay away from the auto trans questions.
Is the Excursion a coil spring or leaf spring chassis, lots of spring choices either way.
4.10 are as low as you'd want with a Cummins, it will tow well but won't like interstate speeds unless your running 35" or taller tires.
You'll need the larger radiator and different front springs to support the added weight.
Not sure about the trans question but I think it would be questionable weather the 5.4's trans could handle the torque of the 5.9.
My Fummins is a manual trans so I usually stay away from the auto trans questions.
Is the Excursion a coil spring or leaf spring chassis, lots of spring choices either way.
Cargo Master
Joined: Dec 2015
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From: Harned, Ky
Wasn't sure, super duty's went to coil spring front in 05.
Depends wether you want stock ride height or lifted, my nephews 7.3 crew bad was sitting lower in the front than he liked, he replaced his 5600 lb springs with 6000 lb for a F-450 that lifted the front 3".
Check the spring code on the door tag to see what it has.
Depends wether you want stock ride height or lifted, my nephews 7.3 crew bad was sitting lower in the front than he liked, he replaced his 5600 lb springs with 6000 lb for a F-450 that lifted the front 3".
Check the spring code on the door tag to see what it has.
Elder User
Joined: Nov 2014
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From: Charles Town, WV
Excursions are way under sprung from the factory, so I'd plan on new springs no matter what. Stock 99-04 Super Duty springs fit in place and support the Ex much better. You should check out the tech folder in the Excursion sub forum here for more info on it.
Most guys are pulling out V10's because most gas Ex's are V10 powered.
Looking at rockauto, the V10 and 7.3 use the same radiator and the 5.4 uses a thinner one (assuming dual core vs single core).
My Ex was fine with the cummins/nv4500 and 3.73's with stock size tires. I have larger tires on it now and wish I had at least 3.93 (which they don't make for the Sterling rear grrr) but may go 4.10's in the future.
Most guys are pulling out V10's because most gas Ex's are V10 powered.
Looking at rockauto, the V10 and 7.3 use the same radiator and the 5.4 uses a thinner one (assuming dual core vs single core).
My Ex was fine with the cummins/nv4500 and 3.73's with stock size tires. I have larger tires on it now and wish I had at least 3.93 (which they don't make for the Sterling rear grrr) but may go 4.10's in the future.
Junior User
Joined: Nov 2016
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From: NE Indiana
You won't be able to use the 5.4 trans because as far as I know no one makes a adapter for a small block trans.
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Cross-Country
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I just bought the engine for this swap out of a 98 Ram 2500 and I see that it's equipped with a transmission cooler that's cooled by the engine's coolant circuit. I'm wondering if I'd be better off sticking with the Ford's air-cooled trans cooler or rerouting the trans fluid lines into the liquid-cooled cooler on the Cummins. I'm thinking that the liquid-cooled cooler is probably more efficient but it means that the trans will be running at engine temperature pretty much all the time where with the air-cooled cooler it'll probably run at a lower temperature unless it's being worked heavily, and then it would be more likely to overheat. I do a lot of pretty heavy towing so this is a concern. Anyone have any thoughts on this?
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Junior User
Joined: Nov 2016
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From: NE Indiana
My 97 Dodge Cummins has both the water and air cooler, but I deleted the water cooler and just use the air. I don't have a trans temp gauge so I don't know if it cools the same as when I had both.
I would think if the air cooler was big enough for the weight your towing it would be enough.
I would think if the air cooler was big enough for the weight your towing it would be enough.
Lead Driver
Joined: Feb 2013
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From: Roseville, MN
Mark Kovalski is a former Ford auto trans engineer who did a lot of work with auto trans coolers in his career. If I recall what he's written in threads like this, it's that the oil-to-water trans coolers are in the cold side of the radiator and are never anywhere near engine temp, so they do cool very well.
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Cross-Country
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This is apparently not a problem with 12V 53 block engines. Only 24V:
Cummins 53 Block Casting Information
Cummins 53 Block Casting Information
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