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Hi all,I have installed a cummins 3.9 cpl 858 105 hp motor in my 89 quigley ford van.It was a tight fit but once installed it looks better than the old straight 6 did.I am going to try to attach a few pictures,will see if it works,they might be to big.The motor I picked up had a ford adapter and a 435 trans so I just pulled it and put in a zf 5 speed.I have only driven it a few miles to gas it up so it will need some tweaking I am sure.Thanks for all the info ,I used the search button and never needed to ask a question !!!
 

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And a few more pictures.Yes this was a budget swap,5,000 total,so yes it can be done.And it was a half ton but I did go and swap in e-250 coils and leaves to help with the weight.The front of the frame was all ready boxed,by quigley or ford ,I dont know.The price was not including the van,I paid 1400.00 for it with a blown 300 straight 6 that I rebuilt and will be installing in my early bronco,unless I come across another 4bt for a good price.Ken
 

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1989 Jeep Wagoneer, 360v8, 727, stock for now,
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Great job! And only $5K! I think my repower was $7K back in 02, but mine was 4x4, extra parts.
Let see more pics of the job.
 

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Thanks,I will resize the pictures and get them up in a few days...
Well I took her for a nice 100 mile ride this morning.The power is great ,did take a little getting use to only shifting around 2,200 but if ya get into her she shows 18 pounds of boost,more than I thought and you can sure feel it.Its cool as you cruse at 55,no boost showing and just give it a little more pedel and ya can hear and feel the turbo doing its job.I have to remove my powersteering pump due to a leak,but should get that done this evening and put some more miles on it in the morning.I need to look into aftercoolers next! I was showing 60 psi oil pressure cold and 40 at idle,and coolent never went over 180 and it is 90 today.I am only using the stock 6cylinder rad with a 2250cfm elec fan and I think it will do the job.KEN
 

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I think my repower was $7K back in 02, but mine was 4x4, extra parts.
Quigley is a conversion company that converts new vans to four wheel drive. I have a friend that has a 2002 Quigley Ford with a 7.3TD. Congrats on the swap, 4wheelvanman!

http://www.quigley4x4.com/
 

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Nice job!!! I have a few questions as I'm getting ready to start my swap into a '69 Ford Econoline NEXT WEEK!!!

How loud is the engine noise? Can you hear the passenger speak? :)

I know I should already know this, but, compared to the 6 cylinder, did you need more room for the 4BT? I have a 302 in my van now, and water pump pully is close to the electric fan already.

Thanks!
Chris

BTW, I wasn't ready to do the swap but other circumstances forced the issue and it needs to be running by July 6th for a trip to Florida...from Oregon. :eek: So, sorry for not searching for this answer about length! :D
 

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Hello.The 300/6 was a lot longer,And the 4bt seems like a perfect fit.The motor noise isnt bad at all,I only have the original dog house insulation,once I add a little more it will be nice and quiet in the vehicle.The sound I have is from the zf,I need a piece of insulation for that!I dont think you will have a problem,the water pump on that 302 sticks out and the front of the 4bt is nice and flat.I think the hardest part with the swap is getting the motor in,there isnt much hight to lift and slide in at the same time,but it can be done,just go nice and slow.I am sure you will love the swap.Ken
Nice job!!! I have a few questions as I'm getting ready to start my swap into a '69 Ford Econoline NEXT WEEK!!!

How loud is the engine noise? Can you hear the passenger speak? :)

I know I should already know this, but, compared to the 6 cylinder, did you need more room for the 4BT? I have a 302 in my van now, and water pump pully is close to the electric fan already.

Thanks!
Chris

BTW, I wasn't ready to do the swap but other circumstances forced the issue and it needs to be running by July 6th for a trip to Florida...from Oregon. :eek: So, sorry for not searching for this answer about length! :D
 

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I really like your conversion, I am partial to the Quigleys, I had a 1988 supervan with 300 six and C6 that I built an AOD to replace it, and now I have a 1996.
My 96 I installed a ZF behind the 5.8...
I modifabbed an older 84-89 E150 clutch pedal assembly to operate a floor mounted master cylinder for mine but am thinking about redoing to whole works.
Curious how well that aftermarket pedal assembly works?
 

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Nice to see some familiar faces (Yakk & Emievel)...

Im in the process of gathering parts...and I have a few questions (and no I didnt read anybody elses yet...im a slacker!!)

do you think the 6cyl would fit?? and do you think the motor could have sat about 4in lower in the frame and not interfere with anything?? (to lower the center of gravity)

thanks man and AWSOME pix...great shots!!
 

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Discussion Starter #11
I really like your conversion, I am partial to the Quigleys, I had a 1988 supervan with 300 six and C6 that I built an AOD to replace it, and now I have a 1996.
My 96 I installed a ZF behind the 5.8...
I modifabbed an older 84-89 E150 clutch pedal assembly to operate a floor mounted master cylinder for mine but am thinking about redoing to whole works.
Curious how well that aftermarket pedal assembly works?
I just used a wildwood cheap pedal and a 1 inch matching master and it works great.k
 

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Discussion Starter #12
Nice to see some familiar faces (Yakk & Emievel)...

Im in the process of gathering parts...and I have a few questions (and no I didnt read anybody elses yet...im a slacker!!)

do you think the 6cyl would fit?? and do you think the motor could have sat about 4in lower in the frame and not interfere with anything?? (to lower the center of gravity)

thanks man and AWSOME pix...great shots!!
There is no way I could get it any lower,I have a dana 44 front and it just clears at full comp.I will be pulling it and installing a 6 12 valve.It will fit but will need core support mods.I feel I am working the 4bt pretty hard towing 10,000 plus the weight of the van,It does great but I want more power for merging and such.I used it to tow down to va and averaged 24.3 mpg!My van sits high but feels stable at speed so I dont mind having the motor sit high.Ken
 

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You will probably need to go 1 ton front if you go 6 cylinder, I would look into the weight ratings. At the least I would truss that front end with the 6.

Maybe just need to turn things up on the 4bt first?

keeping the 4bt would probably save you like 500lbs i'm guessing...
 

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Discussion Starter #14
You will probably need to go 1 ton front if you go 6 cylinder, I would look into the weight ratings. At the least I would truss that front end with the 6.

Maybe just need to turn things up on the 4bt first?

keeping the 4bt would probably save you like 500lbs i'm guessing...
I agree about the added weight,but to get to the power screw I need to pull the motor.I almost dislocated my bad shoulder trying to get to it,lol!I guess I could pull it,do the gov spring,star wheel and power screw,paint and detail the motor and put it back together.I hadent hurd it run for more than 30 seconds before the install and didnt want to paint it up all pretty just to find it needed attention.I need to think about it a little.It sure would be easier to just pull and adjust than do a double motor swap,and a lot cheaper,thats my middle name! Ken
 

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The Ford HP 44 housings are pretty stout. Their weakness under a heavy rig is balljoints. If you're not running big tires or beating it offroad you'd probably be fine with the 6BT and a 44 front. Even under normal use, balljoints wear faster with more weight. You may end up replacing balljoints every 50K miles.

I had a '92 balljoint 60 front under my '70 for awhile and DS balljoints would need replaced every 30K or so with 35" tires. I had a real heavy front winch bumper. The kingpin 60 fronts last forever if you grease them and keep out of water.
 

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The Ford HP 44 housings are pretty stout. Their weakness under a heavy rig is balljoints. If you're not running big tires or beating it offroad you'd probably be fine with the 6BT and a 44 front. Even under normal use, balljoints wear faster with more weight. You may end up replacing balljoints every 50K miles.

I had a '92 balljoint 60 front under my '70 for awhile and DS balljoints would need replaced every 30K or so with 35" tires. I had a real heavy front winch bumper. The kingpin 60 fronts last forever if you grease them and keep out of water.
HP44's are pretty strong but there are also different models. There's a 1/2ton and a 3/4 ton. The 3/4ton is a much stronger housing, with either 3/8 or 1/2" wall tubes. the 1/2ton is lighter duty with i think 1/4" wall tubes. Something to keep an eye out for... the 3/4ton is also a good bit wider. Wms to wms I think they are 67" for 3/4 ton and 63.5" for 1/2 ton. Also, a bunch of the 1/2ton housings had cast in radius arm wedges, if you have these you are stuck with them. if they are welded on, you can cut them off, the cast ones are part of the tube itself.
 

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Discussion Starter #17
Good info on the dana 44 guys,thanks.I got to thinking and my daughter,11 years old says I have small hands,I can get that nut loose.So she reaches in with a 13mm and one second later loose lock nut on the power screw.We removed it and then the little collar and put it back to stock,tested it and it is as it was before removal.I know have turned it in 2 full turns,it now smokes a little at wot,and had to turn down the idle just a bit.I need to bring it for a spin and see ,I have to work till 6 so its going to be a long afternoon!!Will post my findings asap.Will also be watching the egts to see what changes I have in that area.Ken.
 

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Well after a nice long test run with the power screw in two turns all I can say is wow!!! What a difference in power and all around drivability . EGT'S went up about 50-75 degrees across the board.I also went from 16-18 pounds of boost to 22-24 .I am happy with the power and should be able to merge with traffic a little easier !! Will see how fast the fuel gets used up. Ken
 

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:beer: Excellent rig,


I approached quigley about doing a pickup for me instead of a van (Factory Chevy SFA Truck ftw) They never responded :(
 

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what kind of load are oyu towing...Im used to my 460 gasser towing my 7K worht of truck and trailer...sometimes more...but if the BT4 works good...I might go that route...20+MPG...I havent seen that in YEARS in anything I drive other than my ATV!!!
 
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