Engine/Transmission (1994 - 1998) Swap Questions

[KMSCD]

I recently got home from a deployment. I was going to do a bunch of performance mods to the engine I have before putting it in my truck but I had to reprioritize. So, I am going to stick with the E4OD and do some minor things to the engine (replace seals and gaskets, etc, air intake, exhaust, and maybe injectors) then have it put in this coming January or February and when I return to the lower-48, add real power mods and upgrade my transmission.



My questions are:

1. Do I need to buy any parts for the fuel system ('95 5. 9L with P7100 pump into '95 F-350 currently with PSD)? I'll be going to Ford Cummins.com for the conversion parts. When I was going to do mods to the engine prior to the swap, a shop here said I would need a new fuel system (recommended FASS), would that be necessary at this point with doing only minor engine mods?



2. I haven't heard anything bad so far about Bauman, Compushift, or PCS transmission controllers. Anyone have any input on which to go with?



3. Any input on AFE Stage 2 Pro Guard 7 or AEM Brute Force/Work Horse HD air intake systems? AEM is a little cheaper than AFE and I like that both have oil-free filters...



4. Outside of the engine, conversion parts, transmission and controller, is there anything else I'm missing for this swap (I'm having a shop here do the swap for me)?



Thank you!

 

[Missouri Mule]

Check out the Conversion forum and do a search.

 

[KMSCD]

I forgot there is a conversion forum on here! Thank you!

 

[MMcCallie]

As mentioned, check the conversion forum. Read some of my old posts. You'll be much happier with destroked.com parts, they don't get any better. Cummins lift pump will be all you need, don't need a FASS. There is a guy named Matt Heady in Missouri who does a killer job with the E4OD, can even do a manual valve body. He builds monster trucks, even works on Bigfoot.

 

[KMSCD]

I'll do that. Thank you!

 

[CToney]

How many hp is the '95 5. 9 that you have rated for? If it is out of an auto larger injectors wouldn't be a bad idea 215's or some 75hp ddp's. A different plate and gsk (since an auto). A boost elbow will be necessary just keep boost ~30-35 psi. Retorque headbolts and have fun.

 

[Desperado]

You will not need a FASS, the lift pump that is on the engine will be good to over 475HP.

 

[KMSCD]

I'm trying to keep my conversion costs down since I plan on doing major mods when I get back to the lower-48. The motor is completely stock right now. I'm also planning on upgrading to rear disc brakes too. I'm mainly concerned with making it solid because I will be hauling my horse down the ALCAN when I leave here. I'm just trying to make sure I have money left in the bank after the conversion! Things may change in a month and half and I may have the money to add more power mods but I'll be happy just having a Cummins under my hood (and getting better than 13mpg in town)!