OK, been gathering parts and info for this swap for a while now and looking to make it all happen in the next 2 or 3 months. In this thread hope to sort out the final details and update on progress.
Here's an earlier thread where we figured out a plan. http://www.4btswaps.com/forum/showthread.php?26143-05-F250-(gas)-99-5.9-Cummins-G56-6-speed
The recipient, 5.4l gas 6 speed manual, 4x4
The donor
We've also already found and purchased after much searching and many phone calls an 07 Dodge G56 6 speed transmission. That turned out to be the biggest and hardest to find piece of the puzzle, with it we can move forward.
Here's a list of parts to find and notes on what to use, any corrections or better ideas/sources?
I wanted to but don't have time for this whole conversion so I'll help with the research and parts sourcing and the work will be done by friends at my favorite diesel shop.
Next step is take the Dodge truck to the shop, should be there on the 16th. They'll pull the Cummins, clean service, and prep it for the swap.
Then with the engine ready and with a bunch of parts ordered drive the Ford to the shop for the conversion.
I'd be glad to hear about any little things we'll run into so I can make notes and find parts. The more I can do up front the simpler and smoother the swap will go.
Grigg
Here's an earlier thread where we figured out a plan. http://www.4btswaps.com/forum/showthread.php?26143-05-F250-(gas)-99-5.9-Cummins-G56-6-speed
The recipient, 5.4l gas 6 speed manual, 4x4

The donor


We've also already found and purchased after much searching and many phone calls an 07 Dodge G56 6 speed transmission. That turned out to be the biggest and hardest to find piece of the puzzle, with it we can move forward.
Here's a list of parts to find and notes on what to use, any corrections or better ideas/sources?
- Use the existing 5.4L radiator
- 6.0 intercooler, some hardware to go with it
- 6.0 fan shroud and fan
- Second SD passenger side battery tray and hold down, install both on drivers side.
- Run the Dodge alternator with an external voltage regulator.
- Ford Cummins mount kit
- Ford Cummins radiator hose kit
- Air dog lift pump **Any better ideas?
- Southbend clutch and flywheel. Already have the G56 Dodge hydraulic parts.
- 03-07.5 common rail exhaust manifold and if easy to find HE351cw turbo, otherwise stock turbo
- tach sensor/adapter From Destroked,
- Edge programmer CTS, for Gauges, Diagnostics, and Power.
- oil light can use an older small block chevy sensor
- stock dodge Upper water neck
- Downpipe and 4" exhaust system, MBRP with a CR down pipe, and a ford 4" kit
- use the stock Dodge A/C manifold, with hose ends spliced
- Air filter kit ** From who? would like cold air inlet and not just a cone filter under the hood
- Driveshafts modification
- dowel pin fix, engine seals, manifold studs and gaskets, and other preventive maintenance while engine is out
I wanted to but don't have time for this whole conversion so I'll help with the research and parts sourcing and the work will be done by friends at my favorite diesel shop.
Next step is take the Dodge truck to the shop, should be there on the 16th. They'll pull the Cummins, clean service, and prep it for the swap.
Then with the engine ready and with a bunch of parts ordered drive the Ford to the shop for the conversion.
I'd be glad to hear about any little things we'll run into so I can make notes and find parts. The more I can do up front the simpler and smoother the swap will go.
Grigg