E250 4x4 5.9 Cummins Conversion

[MartyAdams]

Another picture and they work.

 

[MartyAdams]

Try to post two this time.

 

[Andy Perreault]

Thanks for posting the pictures, Marty. I've dreamed of doing the same project for years. It has been done, I saw a picture of one on the internet, but the site it was on is long gone. There were no details, just a picture.

I'm thinking, if you have a vertical clearance problem, you may want to install a body lift kit to give yourself more space.

Good luck with your project, and keep us posted.

Andy

 

[MartyAdams]

I am in need of some part number help.

I pulled my cummins from the pickup and the weather turned cold so I did not get the 302 out of the Van. Decided to go over the cummins and fix some of the oil leaks. The vacuum pump was leaking engine oil so I pulled it apart and found the O-ring to the power steering pump flange hardened and also the power steering pump coupling lip seal has a nick out of it. Went to the Dodge dealer and I was told I would need to buy the entire vacuum pump. Called cummins and they told me the same. Is this really the case and do I have to source these parts from my local industrial supply? Does anyone know if dodge or cummins can supply these seals and what the numbers might be?

Thanks

Marty

 

[AKAMAC]

Good thread for you problem

link

 

[BV]

Click Here for a possible solution.

 

[MartyAdams]

Thanks AKAMAC and BV.

I called Tri County Machine and spoke with John. He is sending me the parts right away. Now this kind of help is just what I was after when I joined the membership. Too bad the cummins is going in a Ford EH!!!

Thanks again and good day eh!

Marty javascript:smilie('Oo. ')

javascript:smilie('Oo. ')

 

[DKarvwnaris]

Originally posted by MartyAdams

Hi bmoeller,

I tried fordcummins and I recieved a nice sales pitch that "we are in the process of doing such a swap" but after repeat requests they could not help

Marty

This does not surprise me as they copied their first conversion off of another guys work. My buddy kenny was really upset to see them using the "montanan" name on their website. Kenny is the first guys in the state to be doing cummins repowers, (actaully one of the first in the country to be doing it for customers, he is the one everyone knows in the NHRA alcohol funny car division)

The difference between him and the Kalispell jerk is Kenny won't take someone elses work as his own. He doesn't like talking behind people's back's or speaking poorly of them as it is not his nature. I on the other hand have no respect for the kalispell guy since he is trying to use Kenny's good name and reputation to his own advantage.

Kenny has not done any van repowers that I know of, however, he does have templates to build you a set of Ford to cummins motormounts. The only concerns I would have would be axle/differential clearance issues with the oil pan. The dog house can be modified quite easily if it is too close.

transmission should not be a problem so long as you utilize the entire harness to make sure it shifts correctly, It is controlled by the ECM in 94 models along with the cruise, a/c, charging system etc.

This will be an interesting repower, My main concern will be servicing the engine once installed. I had a powerstroke powered van we leased a few years ago. I will never own one again after having to work on that thing. The turbo housing was leaking around the base/ o rings, what a frustrating two days that was.

 

[MartyAdams]

Thanks for your advice DKarvwnaris.



I expect when I get the engine shoe horned in the acess to the sides of the engine should be really easy. The oil pan clearance will not be a problem with the front differential. The plan is to replace the rad support in the van with the rad support from the pickup. This way the rad and intercooler mounts are all the same. Then all the rad hoses etc. should fit. I expect to have to significantly modify the heater system to make clearance for the turbo. After speaking with John from Tri county machine I learned I could flip the exhaust manifold end for end to change the position of the turbo. This way I may not have to chop such a big chunk out of the fire wall. As for the wiring and electronics this is my background and I have the schematics for both the van and the dodge pickup.

I don't like to talk bad about people or companies and when I did not get the service I hoped for from fordcummins I just moved on. I hope my post was not taken in a negative light as it was intended to represent opportunity lost.



Marty

 

[DKarvwnaris]

Originally posted by MartyAdams



The plan is to replace the rad support in the van with the rad support from the pickup. This way the rad and intercooler mounts are all the same. Then all the rad hoses etc. should fit.

I would look towards a 94 or newer dodge radiator nd see if it fits in there. They bolt to the core support and don;t require the old clamp style mounts at the top and bottom of the tanks. They are much easier to install and hold up alot longer to boot. Core support mods can take up alot of time. Not to mention make it hard to find an off the shelf part if you should hit something like say a deer?

After speaking with John from Tri county machine I learned I could flip the exhaust manifold end for end to change the position of the turbo. This way I may not have to chop such a big chunk out of the fire wall.

If the clearance problem gets to be a real issue, you may consider looking into a different manifold. There so many available for the cummins blocks that I am sure you can find one to relocate the turbo to where you need it without problems. I have used manifolds for farm equipment on dodge 5. 9's with great success in repowers. Most will use the same turbo mounts.

As for the wiring and electronics this is my background and I have the schematics for both the van and the dodge pickup.

Unless you know how to reprgram for the dodge transmission, the cruise, and charging system, you had best use the harness in its entirety for that part. It will also give you the ability to use the dash display out of the dodge for idiot lights etc.

I don't like to talk bad about people or companies and when I did not get the service I hoped for from fordcummins I just moved on. I hope my post was not taken in a negative light as it was intended to represent opportunity lost.

Marty [/B]

I am not one for bad mouthing people either, but this guy is not doing anyone any favors by acting as if he has all the answers and know how. He's been trying to find guinea pigs for Gm repowers for quite a while. He is referring to himself as the Montana cummins guy, which up until around a year or two ago, he didn't exist. Kenny is the one everyone knows from both his funny car builds as well as over 40 repowers. It isn't bad mouthing when you speak with factual information. If you need help, drop Kenny a line, he'll help you with more things than you may think of. 406 727 8915 autoworld in Great Falls, MT

 

[britannic]

I have to say that doing business with Ken @ AutoWorld is great. He just got done fabbing my mounts and refuses to have me pay for them until he's completely happy. He's also sending me pictures of his own truck's setup and instructions on how to adapt mine properly.



I'm happy to pay the extra dollars, because they pay for all of his sage advice.



Thanks for the tip Dave!

Originally posted by DKarvwnaris

I am not one for bad mouthing people either, but this guy is not doing anyone any favors by acting as if he has all the answers and know how. He's been trying to find guinea pigs for Gm repowers for quite a while. He is referring to himself as the Montana cummins guy, which up until around a year or two ago, he didn't exist. Kenny is the one everyone knows from both his funny car builds as well as over 40 repowers. It isn't bad mouthing when you speak with factual information. If you need help, drop Kenny a line, he'll help you with more things than you may think of. 406 727 8915 autoworld in Great Falls, MT

 

[DKarvwnaris]

Glad to hear your happy response, he has always treated me good. One of the few guys who knew what it took to do it once, not twice an at the customers expense.

Good luck with your project, I hope it comes out good for you.

 

[MartyAdams]

The engine bay is now empty and almost ready for a test fit.

 

[MartyAdams]

Just a little photo comparison of the two engnes. The Cummins is huge compared to the wee 5. 0L. This weekend I hope to drop the cummins in place and start fabbing the engine mounts and rad support.

Marty

 

[Andy Perreault]

Marty, the vehicle mechanics at the company I work at are in the process of replacing a blown B5. 9 engine in a Freightliner FL60. I noticed the exhaust manifold is different than it is in our Dodges. The outlet end of the manifold has a 90 degree downward bend in it, and the turbo is mounted below that bend, much closer to the side of the engine block than it is in the Dodge. I just thought you'd like to know about that in case your turbo is sticking too far out from the right side of the engine and you run into clearance problems with the firewall or engine cover. This type of manifold may be a good alternative for your application.

Good luck with your project, keep us posted.

Andy

 

[MartyAdams]

Hi Andy

Thanks for your input on the manifold. I will be running the dodge auto transmission and there is currently an oil cooler located under the exhaust manifold. I don't think there is room to drop the turbo down any father but I would be open to suggestions.



On Monday I finished cutting out the engine mounts as they had been welded due the the engine cross member modification for the 4x4 front axle. Also removed the body cross member / rad support to make room for the dodge rad support. Now to remove the throttle pedal and heater box so that I can start cutting the firewall. I will use the dodge frame mounts on the ford frame. There is currently a difference of 4 1/2 inches from the dodge to ford frame width. I will create spacers for the engine mounts to move the mounts on the engine out farther. I am having a fantastic time with this project!!!! Seriously I can't wait to get it running.





Marty

 

[michigandon]

exhaust manifold

I also had clearance concerns on my repower, so this is the manifold I had to use:

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And yes, this does necessitate the relocation of the heat exchanger. I'm still working out the details on that part.



Don

 

[Andy Perreault]

Marty, I forgot about that oil cooler.

Don, that looks like the same manifold that I saw on the truck at work.

Correction: in my previous posting I had mentioned the truck at work was an FL60. I just noticed today that it's an FL70, although that probably doesn't matter.

Andy

 

[MartyAdams]

Thanks again Don and Andy for the manifold information and the picture. I am not sure I will pursue the manifold for my current refit as I have already planned for modifications to the firewall. It is good to know I have an option if the plan for the heater core does not work. If all goes well or bad I should have a picture of two for Monday.

Marty

 

[MartyAdams]

Stuffed the marshmellow in the piggy bank last week so this means I got the cummins in place and lined up. Here are picks of the engine mounts tacked together. Finished welding them tonight and will paint tomorrow night. Next the transmission mount!