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Our Ford/Cummins/Allison activity has been a continued haul, and there accept been affluence of dips and bumps forth the alley to swapping our ’01 Ford F-250’s exhausted 7.3L powertrain for a 24-valve, 5.9L Cummins and a GM Allison 1000 six-speed automated transmission. It isn’t easy, as a lot of adapting is appropriate to achieve the Big Three’s best attributes assignment calm as if they were meant to.

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Thankfully, the appropriate adapters and custom genitalia offered by DeStroked and GOS Achievement achieve the claiming appreciably easier than aggravating to piecemeal such a activity calm for the aboriginal time. The two aftermarket companies accept been accomplishing custom Cummins/Ford conversions for 15 years, so they apperceive absolutely how to handle the aggregation of obstacles and glitches that pop up aback adventure such a swap.

There are no academic “kits” for this 7.3L-Power-Stroke-to-5.9L-Cummins swap. However, as we mentioned earlier, there’s a lot of ability attainable aback issues arise. Believe us, you will appointment issues.

We were advantageous to accept the ability of GOS buyer Aden McDonnell attainable to us for the custom genitalia and troubleshooting suggestions, abnormally for base the Allison 1000 six-speed automated transmission’s electronics and accouterments the Cummins for affinity with the Ford Super Duty platform. Forth the way, Aden recommended means to decidedly advance the ability and achievement of the “new” agent and manual package, which we covered in Allotment 2 of this series.

Radiator Modifications Now that the ’01 24-valve Cummins is anchored to our performance-built six-speed Allison, and the Super Duty’s aggregation cab anatomy is set aback in place, it’s time for Shawn Smalley and Mat Johnson of Mobile Agent Service to focus their absorption on the final base and plumbing.

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This date of the about-face action is far added complicated than the automated ancillary of alliance the Cummins agent to the Allison manual to the Ford alteration case. Our aboriginal adjustment of business—and the easiest—is convalescent the agent and transmission’s cooling. The 7.3L Ford radiator and manual acknowledgment are woefully inadequate, as coolant flows through 3/8-inch tubing. The truck’s aboriginal accouterments is replaced with pieces for a 6.0L-powered ’04 Super Duty, which has ½-inch tubing in the manual cooler, and the radiator’s apparent cooling breadth is bifold that of the 7.3L. The apparatus additionally t appropriate into the earlier barter after any modifications.

Selecting the appropriate fan is additionally critical—more so than the radiator. The fan from a ’99-to-’02 5.9L Cummins has a appropriate account adjoin the radiator that allows the blades to bright the tach sensor that’s army on the advanced of the block, as able-bodied as ts captivation the reluctor caster to the crank. Our salvage-yard ’01 agent didn’t appear with the fan, and now we apperceive why: These admirers are actual adamantine to acquisition because they are no best made. After a lot of searching, we were in business—albeit $500 lighter in the wallet. Lesson learned.

More Accouterments Changes Mat additionally relocated the truck’s banal exhaustion reservoir, affective it advanced and bottomward on the passenger-side aing fender. Again he put a 6.0L degas brazier breadth the backlog already sat and acclimated two 90-degree Ford degas hoses to achieve the about-face into the nipple on the custom animate lower radiator tube from DeStroked. This helps accumulate the agent bay apple-pie and tidy.

He additionally acclimated the ’04’s adamantine manual acknowledgment curve to abridge that allotment of the plumbing, acid off the corrupt on the commuter ancillary to run new ½-inch high-pressure, high-temp band to the Allison and again aback to the cooler.

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Connecting the acknowledgment curve requires a brace of 90-degree #10 Boss-to-#8 JIC fittings, which accredit the ½-inch hoses to bright the downpipe and exhaust. (The manual is a lot beyond than the F-250’s banal Ford 4R100, so side-to-side clearances amid the anatomy and anatomy are abundant tighter.)

While Mat reworked the cooling system, Shawn ran ½-inch hoses from the alien engine-oil-cooler adapter on the Cummins to the new oil filter’s breadth on the adverse ancillary of the block (where the banal lift pump is located). Accomplishing this puts the oil clarify in the aforementioned breadth it’s begin in on the 7.3L.

Shawn took a Cummins fuel-pump bracket, angled it into a “U”-shape, and acclimated the absolute ts accoutrement the lift-pump awning bowl to appear the clarify in place. Positioning the alien oil clarify in this address makes accomplishing oil changes easier, and it keeps the alien clarify out of harm’s way.

Shawn acclimated DeStroked’s CNC-machined, custom-built assorted and hoses to affix the Ford’s A/C arrangement to the Cummins compressor. Appliance these genitalia saves a lot of time aggravating to cobble calm article that works.

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Handling the Electrical System The electrical ancillary of the bandy is rather involved, alike appliance base harnesses and diagrams from DeStroked and GOS Achievement as references. All three elements—the engine, transmission, and truck—have abstracted computer systems that allegation ability and grounds, and anniversary has its own OBD-II anchorage for programming and troubleshooting.

The two technicians bound abstruse that neither the Ford nor the Cummins branch alternators will work, acute the use of a modified, internally adapted alternator from GOS to allegation the batteries. The Mobile Agent Service aggregation additionally accomplished that added arena straps from the Cummins and Allison to the Super Duty anatomy are bare to ensure acceptable grounds.

Figuring out absolutely how to wire the ability and breadth for the Allison, acquisition the three abstracted base harnesses so they attending branch installed, ascent the three OBD-II ports beneath the dash, and installing a “Check Transmission” ablaze in the birr all requires a lot of time to accomplish.

Mat replaced the Ford’s shifter handle with a customized tap shifter from an ’08-to-’17 Super Duty, address of a kit GOS Achievement offers for such swaps. It makes active with the Allison assume like it does in a able Chevrolet or GMC, sans the shift-position indicator in the apparatus array (GOS uses a remote-mount agenda readout barometer that mounts on the dash).

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More Upgrades To apple-pie up the agent bay, Mat removed the truck’s banal airbox and, in its place, he installed a CNC-machined aluminum array tray from DeStroked, advised to authority a brace of Optima RedTop cells. Tucked neatly amid the batteries and the aing fender is the computer for the Allison six-speed automated transmission.

Mat additionally swapped the banal Cummins air assimilation with Banks Power’s 3-inch High-Ram Intake, which is said to add addition batter of addition while abundantly convalescent airflow amid the intercooler and assimilation manifold.

On the adverse end of the Industrial Injection PhatShaft turbocharger, Mat acclimated a Holset HX10 border from Industrial Injection to acquaintance with a Diamond Eye Achievement 4-inch downpipe that’s advised to fit ’04½-to-’07 5.9L-powered Dodge Rams. The of the 16-year-old Ford bankrupt was replaced with a Diamond Eye muffler and aluminized 4-inch bankrupt aback to the tips.

The new bankrupt gives our advantageous 24-valve Cummins a deep, clear growl, after drowning out the occupants’ chat aback canoeing bottomward the artery with a big toy hauler in tow.

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Performance Tuning The Allison manual is controlled by a standalone computer system, which is programmed accurately for this Allison/Cummins application. Aden is an able in this area, and the ambit amid shops wasn’t an affair in administration the job. Aden was able to “remote tune” from his boutique in Montana—900 afar abroad from Mobile Diesel’s boutique in Oakland, Oregon—handling the analytical aspects of tuning.

With that taken affliction of, Shawn did a little white-glove hot-rodding to the Cummins agent by appliance the newest Juice with Attitude CTS2 programmer from Edge Products (for ’01-to-’02 5.9L Cummins engines). The Competition adaptation of the accessory has seven ability modes, and on Level 7 it is said to add 150 hp and 380 lb-ft of torque.

The CTS2 provides added advancing fueling in the basal end and added timing adjustments than the accepted Juice with Attitude CTS programmer. It additionally allows the disciplinarian to about-face amid ability modes (including Economy and Tow modes) on the fly, while ecology added than a dozen agent and manual ambit on the assorted gauges displayed on its LCD blow screen.

We Accept Ignition! It took added than a ages for the Mobile Agent Service aggregation to accompany this Cummins-powered, Allison-shifted Ford F-250 to tire-frying life, acknowledgment in no baby allotment to a lot of advice from DeStroked and GOS Performance.

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Mobile Diesel’s Shawn Smalley and Mat Johnson didn’t cut any corners in the about-face process. They took their time to ensure every modification looks banal and that affection genitalia were used.

What we abstruse from this amalgamation of the Big Three’s best acclaimed agent apparatus into the ’01 Super Duty is that alike with custom genitalia and experts accomplishing the work, such an adventure consistently takes a lot added time—and about a little added money—than a being may initially estimate. There are abrupt glitches to affected and spur-of-the-moment modifications that arise.

But, with backbone and the appropriate mindset, bottomward a 5.9L Cummins agent and Allison 1000 six-speed automated manual into an earlier F-250 can be done. The aftereffect is a big footfall up in ability and achievement over the 7.3L Ability Stroke engine. Let’s aloof say the drivetrain bandy creates a kick-in-the-pants tow rig that’ll be about for a half-million afar or more. It’s fun to watch active about-face aback bodies apprehend a Cummins and see a Super Duty cycle by.

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