Hi All,
I have been working on this engine swap off and on for the last 5 months. I finally got it out for the first test drive yesterday. I have been doing a play-by-play report over on steelsoldiers.com, but figured you guys would appreciate it too. Here's how it all went down.
I got a 6BT out of a 1995 Ford bus with 92,000 miles on it. It is the 190hp/495lb-ft model with the P7100 pump and a H1C non-wastegated turbo. The humvee came from TX with a locked up 6.2L in it. I had everything in my garage for about 6 months before I ever got started on it because my wife was pregnant with our second boy and I had a bunch of work to do on the house and nursery before any truck projects could get started. I actually got in a time crunch before he was born and swapped another 6.2L in it just to get it running and out of the garage before winter, but that engine ended up having a bad injection pump and some leaky injectors so I yanked it out in frustration. My wife loved that.
OK, so out went the 6.2L. I dug the Cummins out of the corner of the garage, swapped out the front sump pan for a rear sump, tabbed the KDP, stripped the engine down a bit to make it easier to fit and bolted on an adapter plate and billet flex plate. Then, I had to unbolt the HMMWV body and lift it about 12" in order to swing the engine into place. Once I got it in place, I found several points where the chassis was interfering with the engine. The harmonic damper was hitting the front cross-member and the oil pan was hitting the driveshaft yoke and carrier bearing. I decided to move the whole engine, trans, and transfer-case back 3" in the chassis to help everything clear. That really helped out on the front of the engine, plus it took some of the weight off of the front end and improved the weight distribution. I ended up drilling new holes in the carrier bearing mount and shifting it down 3/4" to clear the block/pan.
Once the engine was in, bolted to the trans and sitting level, I began to mock up my mounts. I used 3/8" thick by 4" wide plate to make them. I cut pieces of cardboard to get all of the angles right, transferred the measurements to the steel, cut the pieces on my band saw and then tacked everything together with my Millermatic MIG. I bolted them to the block and the frame mounts to do a final check and then I removed them and welded everything solid.
Once the engine was in I made my 2-1/2" body lift, welded up a downpipe and crossover, installed the serpentine drive and 24v alternator, installed shortened and lengthened driveshafts, installed the radiator, installed a Lokar throttle pedal and cable, installed a manual fuel shut-off from a M35A2 6x6, installed all of the stock sending units to work the humvee gauges, installed a 12/24v starting system (because nobody in the whole world makes a 24v 6.0L Ford starter), installed the intercooler )thanks Phil), fabbed the intake and intercooler plumbing, installed a 24v electric fan system with thermostat and installed the front clip.
I did all of my final cleanup, fluid filling and bolt tightening on Sunday before taking it on the maiden voyage. What a blast! What a great sound! What power compared to the 6.2L! Enjoy the pics and videos.
I have been working on this engine swap off and on for the last 5 months. I finally got it out for the first test drive yesterday. I have been doing a play-by-play report over on steelsoldiers.com, but figured you guys would appreciate it too. Here's how it all went down.
I got a 6BT out of a 1995 Ford bus with 92,000 miles on it. It is the 190hp/495lb-ft model with the P7100 pump and a H1C non-wastegated turbo. The humvee came from TX with a locked up 6.2L in it. I had everything in my garage for about 6 months before I ever got started on it because my wife was pregnant with our second boy and I had a bunch of work to do on the house and nursery before any truck projects could get started. I actually got in a time crunch before he was born and swapped another 6.2L in it just to get it running and out of the garage before winter, but that engine ended up having a bad injection pump and some leaky injectors so I yanked it out in frustration. My wife loved that.
OK, so out went the 6.2L. I dug the Cummins out of the corner of the garage, swapped out the front sump pan for a rear sump, tabbed the KDP, stripped the engine down a bit to make it easier to fit and bolted on an adapter plate and billet flex plate. Then, I had to unbolt the HMMWV body and lift it about 12" in order to swing the engine into place. Once I got it in place, I found several points where the chassis was interfering with the engine. The harmonic damper was hitting the front cross-member and the oil pan was hitting the driveshaft yoke and carrier bearing. I decided to move the whole engine, trans, and transfer-case back 3" in the chassis to help everything clear. That really helped out on the front of the engine, plus it took some of the weight off of the front end and improved the weight distribution. I ended up drilling new holes in the carrier bearing mount and shifting it down 3/4" to clear the block/pan.
Once the engine was in, bolted to the trans and sitting level, I began to mock up my mounts. I used 3/8" thick by 4" wide plate to make them. I cut pieces of cardboard to get all of the angles right, transferred the measurements to the steel, cut the pieces on my band saw and then tacked everything together with my Millermatic MIG. I bolted them to the block and the frame mounts to do a final check and then I removed them and welded everything solid.
Once the engine was in I made my 2-1/2" body lift, welded up a downpipe and crossover, installed the serpentine drive and 24v alternator, installed shortened and lengthened driveshafts, installed the radiator, installed a Lokar throttle pedal and cable, installed a manual fuel shut-off from a M35A2 6x6, installed all of the stock sending units to work the humvee gauges, installed a 12/24v starting system (because nobody in the whole world makes a 24v 6.0L Ford starter), installed the intercooler )thanks Phil), fabbed the intake and intercooler plumbing, installed a 24v electric fan system with thermostat and installed the front clip.
I did all of my final cleanup, fluid filling and bolt tightening on Sunday before taking it on the maiden voyage. What a blast! What a great sound! What power compared to the 6.2L! Enjoy the pics and videos.
