CUMMINS CONVERSIONS

Fummins is a Ford with a Cummins engine.

Swapping a Cummins engine into a 1999-2010 Ford Super Duty is a popular modification among truck enthusiasts who want to combine the reliable Cummins engine with the durability of the Ford Super Duty frame & Cab. This type of engine swap can offer the benefits of a powerful and efficient diesel engine without the complexities and potential issues associated with newer emissions systems like DEF (Diesel Exhaust Fluid) and emissions controls. Here's an overview of what's involved in such a swap:

1. Engine Selection:

Select a Cummins engine that is compatible with the Ford Super Duty's chassis and drivetrain. The most common choice is the Cummins 5.9L engine (commonly referred to as the 12-valve or 24-valve engine). The 6.7L Cummins engine can also be used with the appropriate modifications.

2. Engine Preparation:

Prepare the Cummins engine for installation by ensuring it is in good condition, making any necessary repairs or upgrades, and gathering any additional components needed for the swap.

3. Custom Fabrication:

Since the Cummins engine was not originally designed to fit into a Ford Super Duty, some custom fabrication work will be necessary. This includes modifying engine mounts, transmission mounts, exhaust system, and potentially the cooling system to ensure proper fitment.

4. Transmission Compatibility: To maintain the OEM drivetrain functionality, the Cummins engine needs to be mated to the existing Ford transmission. Adapters or custom bell housings needed to connect the Cummins engine to the Ford transmission.

5. Electronics and Wiring:

The engine control modules (ECMs) and wiring harnesses of the Cummins engine and the Ford Super Duty will need to be integrated. This may require some rewiring and modifications to ensure that all engine functions, as well as features like air conditioning and cruise control, work as intended.

6. Cooling System:

The cooling system will need modification to accommodate the Cummins engine. This includes radiator upgrades, intercooler installation (if applicable), and modifying hoses and connections.

7. Exhaust System:

The exhaust system will need to be custom-designed to fit the Cummins engine and meet emissions regulations if applicable in your area. Proper exhaust routing is important for engine performance and sound.

8. Drivetrain and Transfer Case:

The drivetrain and transfer case will need modifications to handle the increased torque and power of the Cummins engine. Upgrades to components like driveshafts and axles might be necessary.

9. Tuning and Testing:

After the engine swap is complete, the vehicle will need to be properly tuned to ensure optimal performance and drivability. Extensive testing and adjustments might be needed to fine-tune the engine's performance.

It's important to note that an engine swap of this nature is a complex and involved process that requires a good understanding of automotive mechanics, fabrication skills, and access to specialized tools. If you're not experienced with these aspects, it's recommended to consult with professionals who specialize in engine swaps or diesel performance modifications to ensure a successful and reliable outcome. Additionally, consider the legal and emissions implications in your region before proceeding with such a project.

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Common rail 5.9 Cummins mated to a Ford 5R110 with custom stall Torque Converter