2003-2007 Ford 6.0L Diesel

INFORMATION FOR ALL 6.0L MODELS

The Ford® Super Duty® 6.0L trucks are the easiest trucks to convert to Cummins® power.  No modifications to the firewall, core support or floor pan are necessary.  The stock radiator, intercooler and fan shroud can all be used as is with the Cummins engine.  In some cases, it is possible to move the transmission back just enough to use an engine driven radiator fan with our custom carrier bearing mount and still retain the stock drive shaft length.  We make this bracket available to you after you have determined your stock drive shaft has enough slip remaining for suspension travel and drive shaft compression needs. 
When you buy Diesel Conversions® parts we include year specific installation instructions.  This includes wiring instructions for customers using the 12-Valve 6BT or the 1998 ½ - 2002 24-Valve Cummins engines, or if you would prefer, you can opt to have us do the bulk of the wiring work for you by sending in your 6.0L engine harness to be modified, as we do with the 2003 and newer Cummins engines.

TRANSMISSIONS

6.0L AUTOMATICS
5R110-
These transmissions work well in the conversion.  Many of our customers have used them behind a 400+ horsepower Cummins just the way they are, including the stock torque converter.  You do not have to do any grinding to the bell housing for starter clearance. Our adapter plate and custom flex plate uses the stock converter configuration, saving you from having to buy a custom dimensioned torque converter.

Currently it is recommended to use an aftermarket transmission controller with this transmission, unless you qualify for our Ford TCM tuning option.  A laptop computer is required when using the aftermarket transmission controller to work together with us to get the final shift tuning just right or load different calibrations into the controller.

We pre-calibrate your transmission controller according to your tire size and gear ratio as close as possible before we send you the controller.

After you get your truck running, we plan on helping you learn how to use the laptop computer to data-log the transmission shifting and receive edited calibrations from us via e-mail.  This tuning support is included in the mandatory pre-programming and technical support fee that you will see in our kit prices.  Also, included in this fee are modifications to the transmission controller harness we include with the transmission controller.  These modifications make installation much easier for the installer.  Believe us, these services are money well spent!

Be prepared that when you first get your truck running the transmission may not shift properly and tuning can take a few days, exchanging 10 or more data-logs for edited calibrations.  You also need to know that you will lose the switch-able tow/haul features that your transmission now has.  Your tow/haul switch can only function as a cancel overdrive feature.  The tow / haul switch becomes a cancel overdrive switch only, and engine braking can only be utilized in third and fourth gears, regardless of tow / haul selection.  So be prepared that the convenience of pushing the tow/haul button to toggle between ‘normal’ and ‘tow/haul’ will be lost with the conversion.  It is still possible however, to have another calibration that you can load into the controller with your laptop whenever you wish, and we can provide tuning that has automatic downshifts with engine braking at zero percent throttle if desired.

See our Cummins to Ford 5R110 Torqshift article for more information.

DODGE® AUTOMATICS
Currently Diesel Conversions® does not offer any technical support for these transmissions.

FORD 6.0L 6-SPEED MANUAL
Diesel Conversions® makes an adapter for the 6.0L diesel 6-speed that uses the Ford 6.0L starter, and absolutely no grinding of the transmission or Cummins engine is required for starter clearance.   Ford started using this transmission design in 1999, and they work well behind the Cummins.  They are rated for 520 ft. / lbs. of torque.

The 6.0L 6-Speed manual transmission adapter plate can use the 6.0 single mass design clutch with our custom flywheel.  Some stock application 6.0L’s have a dual mass clutch, but these will not work with the Cummins conversion.  If you have a dual mass clutch, we recommend using a Ford 7.3 clutch- and we can set you up with the correct configuration.
 

INFORMATION ABOUT PARTS IN OUR KITS

ADAPTER PLATES
Diesel Conversions® adapter plate for the 6.0L Super Duty uses the stock 6.0L Ford starter. No modification is required to the transmission bell housing.  This adapter plate uses either our custom flywheel or custom flex plate. The adapter plate replaces the adapter already on the back of the Cummins engine, making a factory quality connection for the transmission.  They are precision machined from aircraft grade (6061) aluminum.

ENGINE MOUNTS
Our motor mounts are pre-drilled to accommodate either the Cummins engine driven fan or electric fans.  The engine mounts are an excellent design with a bolt going all the way through the isolator, instead of relying on rubber and weak interlocking tabs to secure them to the frame cross member.

Even though it is possible to use electric fans, we do not recommend doing so, as we have heard back from some customers that did and experienced cooling problems as a result.  Using electric fans don't necessarily save you money or work either.  In some rare cases, it may be possible to utilize our custom carrier bearing mount, which may make it possible to use your drive shafts as they are- even with the engine driven fan.  This mount replaces your stock carrier bearing mount and moves the carrier bearing back just enough to give you room for the engine driven fan by collapsing the slip joint in your rear drive shaft.  It is necessary for you to make sure you will still have enough slip in the joint when your rear suspension is compressed.  Usually the rear drive shaft is fairly level in trucks that do not have a lift kit, so the drive shaft does not need to collapse very much during suspension travel.  In most cases the front drive shaft on four-wheel drives will stretch enough to reach the front differential. 

It is necessary to move the transmission cross member back or lengthen the slots in the mount to slide the transmission back enough to give room for the engine driven fan. Automatic trucks already have holes in the frame to move the cross member back to accommodate the Dodge Cummins engine driven fan. 

GAUGE SENDING UNIT ADAPTERS (BUSHING KIT)
Diesel Conversions® custom builds adapters to put your Ford gauge sending units into the Cummins engine so that your stock gauges still work, with the Cummins engine, when used in conjunction with the tachometer kit.

ALTERNATOR MOUNT
Diesel Conversions® offers an alternator mount that allows you to use the 6.0L alternator if you would like.  The advantages of using this alternator is that your indicator light will still work as it should if your charging system should fail.  If you would rather use the Dodge Cummins alternator, we can provide you with an external voltage regulator kit. This kit includes a wire pigtail and instructions. Common Rail applications do not need the external regulator, even with the Dodge alternator. 

EXHAUST MANIFOLDS
Diesel Conversions® sells exhaust manifolds that work much better in the conversion for the 12-Valve and 1998 ½ - 2002 24-Valve engines.  These manifolds place the turbo in a better place for A/C box clearance than the stock variety, and also make exhaust and turbo oil drain connections easier as well. 

For the 24-Valve engines, other exhaust pieces are necessary when using our exhaust manifolds to provide an adjustable elbow connection for the downpipe.
Both of these manifolds require you to re-orient your turbo housings to allow your oil drain to be pointed down correctly.  This usually requires you to heat the exhaust housing on the turbo to remove the bolts and the housing so the housing can be re-oriented.  Either fixing the waste gate shut or using a different waste gate actuator we can provide is also necessary because once the turbo is re-oriented the actuator will hit the engine block.  Fixing the waste gate shut does not usually have any adverse effects on the engine, but we do recommend using a boost gauge to monitor and limit boost pressures to less than 40 PSI. 

Diesel Conversions® also offers manifold gaskets, and new exhaust manifold to turbo studs if you would rather not try to get the studs out of your stock manifold.  Also helpful is a flexible turbo drain tube that connects to the stock hose and elbow that is left in your engine block when you remove the stock drain tube connected to the turbo.  If you would rather, it is possible to heat your stock tube up to bend and twist it to allow reconnecting it after you re-orient your turbo housings.

TACH KIT
The tach kit consists of the Base, Mount, Sensor, and tach ring.  These parts are necessary to make your factory tachometer work.  Providing this signal to your Ford PCM computer also is necessary for the air conditioning, factory transmission control, and for the transmission temperature gauge to work as well.  The universal sensor and mount we offer is the easiest way to supply the tach signal.  We will have a mount for the stock 6.0L crank sensor for 12 and 24 valve models soon.

Most 12-Valve engines 1994 and newer already have the tach sensor base, which is bolted to the front cover at about 11:00 to the balancer. You will have to drill and tap a hole in it for our sensor mount to bolt to it. 

6.0L trucks using a 12 valve or 24 valve Cummins require the tach ring that bolts onto the front of the Cummins crankshaft balancer for the sensor to generate the correct signal pulse to the Ford PCM that makes the tachometer work.

Customers using the 2003-2012 Common Rail engine are offered a bracket to mount the 6.0 crank sensor to read the OEM Cummins tone ring.  This is much better than electrical converter boxes other companies offer- and saves you money too!

TRANSMISSION CONTROLLER
See our Cummins to Ford 5R110 Torqshift article for more information.

AIR FILTER KIT
Diesel Conversions® sells air filter kits which contain a Brute Force air filter, steel elbow, and a hose to connect to your turbocharger.  We offer two styles of air filter kits.  The DCS Part #1943 positions the Brute Force air filter between the passenger side battery and the radiator.  This is especially the kit to use if you are using a Common Rail style turbo.  Even though the passenger side intercooler tube is a bit more challenging when using this kit with a 12-Valve style turbo, this kit saves you a lot of work moving the passenger side battery. 

The second kit, DCS Part #1941, is mainly offered for those who would prefer more room for the air filter.  It requires relocating the passenger side battery to the driver’s side. This takes some fabricating skill to make the brackets to mount the passenger side battery tray and another one just like it on the driver’s side, but it provides a nice roomy area for the air filter.

A/C MANIFOLD
This A/C manifold bolts to the back of a 1994 and newer Dodge A/C pump, making the A/C plumbing less of a challenge.  All you will need to do is have some new hoses crimped between our manifold and a 1999 style A/C tube at the drier (a picture of one is in our manual), and the stock line connected to your condenser. 

RADIATOR HOSE KIT
This radiator hose kit includes the radiator and heater hoses that work well in the conversion and a specially bent aluminized steel lower radiator hose connector tube along with hose clamps. The kit that is offered in our kit builder only works with the stock radiator and a new style water connection as shown on our Cummins Engine Information page. 

PEDAL BRACKET KIT
Our pedal bracket kits are offered for those customers that have adjustable pedals or want to use their existing pedal for a throttle position sensor.   See the Ford Throttle Pedal Identification article to identify your pedal.

WIRING HARNESS SERVICES
Diesel Conversions® can provide you 6.0L engine harness modification services that make wiring much less of a challenge.  We modify your 6.0L engine harness to connect to a Cummins engine harness, providing your Ford PCM the signals it needs to make your factory gauges work.  This service is normally included in packages for those using the 2003 and newer Common Rail Cummins engines, as we do not provide wiring instructions for do-it-yourselfers for this specific engine.  This service is optional for the 12-Valve and 1998½ - 2002 24-Valve engines, as we do provide wiring instructions for these engines when you buy parts for your conversion.  

PARTS YOU WILL NEED TO GET ON YOUR OWN

Even if you buy everything we sell, you will need to come up with a few parts on your own, such as an exhaust down pipe (usually a Dodge down pipe can be a good start), and intercooler tubes (again Dodge stuff can be a good start).  We may be able to supply you with these, but our supply is limited at this time.
Depending on your application, you may also need a Ford gas powered truck’s gas pedal, a Dodge throttle cable, and a Ford gas powered truck’s cruise servo. When you order parts, we can tell you exactly what you will need; we may even be able to supply these parts for you.

Automatic transmission equipped trucks will require a throttle position sensor.  Depending on the year and what transmission your Cummins engine had on it originally, you may need to purchase a throttle position sensor, or look into other options, such as our using the Ford pedal with our pedal bracket kit.  All 24-Valve engines already have a throttle position sensor that can be used for the transmission controller.
 
Industrial Engines
Sometimes customers buy engines out of industrial applications.  These engines may not have the correct brackets for conversion friendly accessories. See the Cummins Engine Information page for more information.

CONSIDERING HAVING US DOING THE CONVERSION FOR YOU?
 

Give us a call and find out how Diesel Conversions® can do a professional conversion on your truck for a reasonable price. We have an international airport for travel from and back to our shop, and also can help with shipping options getting a disabled truck here.

NEW, REBUILT, OR USED ENGINES FOR SALE

This information is provided to you to help you make an informed decision on your conversion.  If you have any questions do not hesitate to contact us.

*Diesel Conversions® is not affiliated with Cummins, Ford, or Dodge.  Our use of these registered trademarks is for descriptive purposes only.

Diesel Conversions®
Diesel Conversion Specialists
www.dieselconversion.com
406.755.8878

Knowledgebase Topic: 
Make of Truck: 
Ford
Year of Ford Truck: 
2003-2007
Adaptable Transmissions: 
Ford 6.0/6.4 5R110 AT
Ford 2003-2010 6.0 ZF-6 MT
Adaptable Cummins Engines: 
1989-1993 5.9L 12-Valve (Gen-1)
1994-1998 5.9L 12-Valve (Gen-2)
1998.5-2002 5.9L 24-Valve
2003-2012 5.9L or 6.7L Common Rail