Swapping a 89 IDI Automatic with a 97 PSD 6 speed
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Swapping a 89 IDI Automatic with a 97 PSD 6 speed
So the title says it all, i have a donor 97 PSD that will get a complete rebuild (including new injectors and HPOP) i will probably need a new wiring harness and still need to find a transmission. this is going into a 89 IDI Dump truck i own part of this whole swap will include making the dump truck 4x4. i am looking for suggestions and advice, specifically the following: What front axle to use/look for, What i will need to mechanically mount the motor in the truck, what i will need to do as far as electrical and wiring harnesses go, what to do with computers, and what can be upgraded on the 97 7.3 to make the motor more modern (like larger injectors) and higher performance with minimal loss to longevity (it is a work truck) Please help!! also donor motor is missing turbo.
Cargo Master
Joined: Jul 2015
Posts: 3,076
Likes: 21
From: Aransas Pass, Tx
Hey man welcome to the forum. You can go as crazy or as simple as you want, all depending on your budget. First things first:
Dana 60 will be the most common front end seen in these trucks that are worth anything. Solid, robust, and easily sourced but expensive.
You'll need the motor mounts to put the engine in the truck. If you don't have them, RockAuto will have what you need. After that, you'll need to probably cut out the original and install a custom engine cross member. Hopefully you're handy with a welder.
Wiring: You'll need the complete wiring harness from the donor truck, including the trans harnesses and the wires that go to the rear end (Another reason to re-use the 10.25 rear) especially if you have an auto transmission.
What power level are you looking for? 300? 400? 550? That will tell you what injectors and turbo to go with. Stage 1 injectors with a stock turbo or maybe a S366SXE T4 turbo, depending on how much you want to spend.
Put pictures up! We like pictures.
Dana 60 will be the most common front end seen in these trucks that are worth anything. Solid, robust, and easily sourced but expensive.
You'll need the motor mounts to put the engine in the truck. If you don't have them, RockAuto will have what you need. After that, you'll need to probably cut out the original and install a custom engine cross member. Hopefully you're handy with a welder.
Wiring: You'll need the complete wiring harness from the donor truck, including the trans harnesses and the wires that go to the rear end (Another reason to re-use the 10.25 rear) especially if you have an auto transmission.
What power level are you looking for? 300? 400? 550? That will tell you what injectors and turbo to go with. Stage 1 injectors with a stock turbo or maybe a S366SXE T4 turbo, depending on how much you want to spend.
Put pictures up! We like pictures.
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Thanks Jarrett!
I figured i would go with a dana 60, but i have no clue what the gearing in the rear end of the truck is, also will i need a rear front end from a dually?
Will the motor mounts be the same or will i need adaptor motor mounts?
i am looking to put a 6 speed transmission in the truck and i do not have a donor truck unfortunately, i still need to source a 6 speed trans and clutch, transfer case and front axle and wiring harness.
How do i add my pictures to the post?!?! i uploaded them to the site?
Thanks for the help, totally new to forums!!
as far as how i build the motor goes, i am looking fro strong performance but not something where i am going to be blowing up engines and things, i think and overbuilt 400HP would work nicely it is a dump truck so it will be pulling alot, also i live in the mountains so its all hills.
I figured i would go with a dana 60, but i have no clue what the gearing in the rear end of the truck is, also will i need a rear front end from a dually?
Will the motor mounts be the same or will i need adaptor motor mounts?
i am looking to put a 6 speed transmission in the truck and i do not have a donor truck unfortunately, i still need to source a 6 speed trans and clutch, transfer case and front axle and wiring harness.
How do i add my pictures to the post?!?! i uploaded them to the site?
Thanks for the help, totally new to forums!!
as far as how i build the motor goes, i am looking fro strong performance but not something where i am going to be blowing up engines and things, i think and overbuilt 400HP would work nicely it is a dump truck so it will be pulling alot, also i live in the mountains so its all hills.
Cargo Master
Joined: Jul 2015
Posts: 3,076
Likes: 21
From: Aransas Pass, Tx
If you can find a front from a dually, that is great, but you can also get dually hubs (although they are pretty pricey). Motor mounts, I am not sure. I would think that since you can swap front clips, the frames would be the same but I have never been down this road so I don't know for sure. If you're handy with a welder, you won't have any issues though.
For the trans, ZF6 are only available from the 1999-2003 trucks. They're also significantly bigger than the ZF5 transmissions that came in the OBS generation. With the 6spd you might have to open up the trans tunnel, ZF5 you might not.
You might have to post a few more times before you have picture privileges but when you get them, you just click on the "mountain" picture next to your text options in the top bar of the reply box, and follow the instructions to upload the picture.
400HP is a good power level in my opinion. Sounds like you'll have a beast of a truck!
For the trans, ZF6 are only available from the 1999-2003 trucks. They're also significantly bigger than the ZF5 transmissions that came in the OBS generation. With the 6spd you might have to open up the trans tunnel, ZF5 you might not.
You might have to post a few more times before you have picture privileges but when you get them, you just click on the "mountain" picture next to your text options in the top bar of the reply box, and follow the instructions to upload the picture.
400HP is a good power level in my opinion. Sounds like you'll have a beast of a truck!
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