Conversion... the full Monte
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Cargo Master
Joined: Jun 2013
Posts: 2,079
Likes: 63
From: Florida and Tennessee
Conversion... the full Monte
2002 Ford Excursion limited, 7.3 Power Stroke 4WD.
Well I'm seriously considering a large conversion project on my truck. Beyond the cosmetics the project will be/include many upgrades to bring the truck into a more modern, capable, better riding, more reliable vehicle. Won't be cheap and will take a long time.
1. Convert leaf spring front axle to coils (2005-07) front end/rear end
2. Convert 7.3 PSD to the 5.9, 24 valve Cummins with P-pump
3. Convert 4R100 4 speed transmission to a 6 speed Allison
Of course those of you who have done these type projects know it's a body off frame conversion. I will do as much as I can, such as the engine build (maybe). I could do it all, but I'd rather not at my age. All the aspects of the conversion(s) have after market support with kits to complete the conversion. I've done the coil spring conversion on another vehicle without pulling the body.
I may still opt to keep the 7.3 PSD, but I'd love to have a mechanical 5.9 and get rid of the electronics and the HEUI injector system the Power Stroke uses. My 7.3 is a good engine with less than 200K. Runs strong, pulls hard, very reliable, but the 5.9, 24 valve Cummins is the bomb. If any of you gear heads have some input or knowledge... would love to hear it.
Budget is good 50K + (including cosmetics/interior/exterior) This will be a legacy build with my son and grandson. This "new" truck will be mostly for towing, family vacations and will not (maybe) be a daily driver.
Well I'm seriously considering a large conversion project on my truck. Beyond the cosmetics the project will be/include many upgrades to bring the truck into a more modern, capable, better riding, more reliable vehicle. Won't be cheap and will take a long time.
1. Convert leaf spring front axle to coils (2005-07) front end/rear end
2. Convert 7.3 PSD to the 5.9, 24 valve Cummins with P-pump
3. Convert 4R100 4 speed transmission to a 6 speed Allison
Of course those of you who have done these type projects know it's a body off frame conversion. I will do as much as I can, such as the engine build (maybe). I could do it all, but I'd rather not at my age. All the aspects of the conversion(s) have after market support with kits to complete the conversion. I've done the coil spring conversion on another vehicle without pulling the body.
I may still opt to keep the 7.3 PSD, but I'd love to have a mechanical 5.9 and get rid of the electronics and the HEUI injector system the Power Stroke uses. My 7.3 is a good engine with less than 200K. Runs strong, pulls hard, very reliable, but the 5.9, 24 valve Cummins is the bomb. If any of you gear heads have some input or knowledge... would love to hear it.
Budget is good 50K + (including cosmetics/interior/exterior) This will be a legacy build with my son and grandson. This "new" truck will be mostly for towing, family vacations and will not (maybe) be a daily driver.
Fleet Mechanic
Joined: Mar 2023
Posts: 1,602
Likes: 945
Sounds like a awesome build. Please do a build thread for it (with lots of pictures).
I recently got a Cummins 12 valve with NV4500 manual trans swap done in my 05 Excursion. I did a build thread for it over on CumminsForum (see link below). It doesn't have to be a body off project if you don't want it to be.
https://www.cumminsforum.com/threads...e-way.2557973/
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I recently got a Cummins 12 valve with NV4500 manual trans swap done in my 05 Excursion. I did a build thread for it over on CumminsForum (see link below). It doesn't have to be a body off project if you don't want it to be.
https://www.cumminsforum.com/threads...e-way.2557973/
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Fleet Mechanic
Joined: Jan 2017
Posts: 1,667
Likes: 182
Sounds like a great project! Any plans as to how you're going to make the Allison trans work? I'm sure there's stuff out there to make it go, but honestly I haven't seen many folks do that conversion because of the electronics/controls required for that transmission. Tons of folks converting the 24V to a p-pump. Have you also looked at the 6.7 p-pump conversions?
Fleet Mechanic
Joined: Mar 2023
Posts: 1,602
Likes: 945
IMHO the Allison is way overrated.
I’d take the 4r100 you already have or a 5r110 or the 6r140 over the Allison. If you want an automatic.
if you’re open to a manual transmission, then the zf-6 would be freaking sweet.
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I’d take the 4r100 you already have or a 5r110 or the 6r140 over the Allison. If you want an automatic.
if you’re open to a manual transmission, then the zf-6 would be freaking sweet.
…
Thread Starter
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Cargo Master
Joined: Jun 2013
Posts: 2,079
Likes: 63
From: Florida and Tennessee
Sounds like a great project! Any plans as to how you're going to make the Allison trans work? I'm sure there's stuff out there to make it go, but honestly I haven't seen many folks do that conversion because of the electronics/controls required for that transmission. Tons of folks converting the 24V to a p-pump. Have you also looked at the 6.7 p-pump conversions?
https://www.caconversions.com/
Thread Starter
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Cargo Master
Joined: Jun 2013
Posts: 2,079
Likes: 63
From: Florida and Tennessee
To be family friendly... I'm only gonna consider the automatic. I prefer the 6 peed Allison for so-SO many reasons behind the Cummins.
Fleet Mechanic
Joined: Mar 2023
Posts: 1,602
Likes: 945
Is there a particular reason you want the 05-07 front end? The 08+ axles has some upgrades stock compared the 05-07 units. If you're swapping the axles anyway, why not go for the 08+ axles?
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Cargo Master
Joined: Jun 2013
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From: Florida and Tennessee
Tell me why 08 is a 'better' upgrade?. ..
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Fleet Mechanic
Joined: Mar 2023
Posts: 1,602
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Larger unit bearings, better brakes, better steering drag link design (that design can't have tie rod roll which causes a dead spot in the steering), overall just stronger. They even changed the name of them to "super dana 60".
And they should be easier to find as well. While Ford made a bunch of 05-07 trucks, that's still only three model years worth of production, the 08+ stuff has been going on 15 years of production, so there are just more of them out there. That and people are practically giving away 08-10 trucks with blown up 6.4's in them.
I have both an 05 Excursion that I swapped an 04 superduty dana 60 into (the 4x4 Excursions all came with dana 50's for some reason), and a 2010 F250. Having worked on and driven both ,the 08+ stuff is just better. Oh, the 08+ trucks also got a better steering box too, might consider swapping that in while you're at it.
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And they should be easier to find as well. While Ford made a bunch of 05-07 trucks, that's still only three model years worth of production, the 08+ stuff has been going on 15 years of production, so there are just more of them out there. That and people are practically giving away 08-10 trucks with blown up 6.4's in them.
I have both an 05 Excursion that I swapped an 04 superduty dana 60 into (the 4x4 Excursions all came with dana 50's for some reason), and a 2010 F250. Having worked on and driven both ,the 08+ stuff is just better. Oh, the 08+ trucks also got a better steering box too, might consider swapping that in while you're at it.
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Laughing Gas
Joined: Jan 2020
Posts: 831
Likes: 171
From: Greenville, TX
The revisions in '08 cause more workarounds which will cost you time and money. I'd stay with the 05-07 axles, they'll give you the extra beef without (as many) headaches.
Browse Nicmike's thread for more details
Browse Nicmike's thread for more details
Fleet Mechanic
Joined: Mar 2023
Posts: 1,602
Likes: 945
The revisions in '08 cause more workarounds which will cost you time and money. I'd stay with the 05-07 axles, they'll give you the extra beef without (as many) headaches.
Browse Nicmike's thread for more details
Browse Nicmike's thread for more details
I'm guessing he's down for the struggle.
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Thread Starter
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Cargo Master
Joined: Jun 2013
Posts: 2,079
Likes: 63
From: Florida and Tennessee
The revisions in '08 cause more workarounds which will cost you time and money. I'd stay with the 05-07 axles, they'll give you the extra beef without (as many) headaches.
Browse Nicmike's thread for more details
Browse Nicmike's thread for more details
Laughing Gas
Joined: Jan 2020
Posts: 831
Likes: 171
From: Greenville, TX
Lol you've got a valid point there
Fleet Mechanic
Joined: Mar 2023
Posts: 1,602
Likes: 945
Anyone can do that, its called "custom cars by wallet", which as we all know, is way lame. While I don't particularly care for the Allison trans he wants to use (regardless of what CA Conversions says, I mean they make money selling Allison's, of course they're gonna talk it up), the idea of a P-pump 24 valve with a custom controlled automatic and coil spring front is way cooler than an off-the-shelf store bought rig.
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