1999-2003 Ford® 7.3L Diesel
Posted by Diesel Conversion Specialists® on Oct 15th 2020
INFORMATION FOR FORD® 7.3L SUPER DUTY® TRUCKS
The Ford Super Duty 7.3L trucks are one of the easiest trucks to convert to Cummins® power. No modifications to the firewall, core support, or floor pan are necessary. The stock radiator and intercooler can all be used as is with the Cummins engine, and the fan shroud works with minimal modifications.
When you buy Diesel Conversions Specialists® (DCS) parts, we include installation instructions. This includes wiring instructions for customers using the 12-Valve 6BT or the 1998½ - 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 7.3L engine harness to be modified, as we do with the 2003 and newer Cummins engines.
TRANSMISSIONS
FORD STANDARD TRANSMISSIONS
Ford 5-Speed: We make adapter plates for these transmissions that use the 2003-2007 Ford 6.0L diesel starter and require no grinding as long as the transmission was behind a 7.3L diesel. We offer adapter plates that use the Dodge® Cummins starters for the 7.3L diesel or 460 big block 5-speeds. These adapter plates require grinding of the starter pocket for starter to transmission clearance.
The 1995 and newer transmissions are rated for 470 ft. / lbs. of torque.
Ford 6-Speed: We make adapter plates for the 7.3L and 6.0L diesel 6-speed. These are very good transmissions for the conversion. Currently, we offer an adapter plate that uses a 2003-2007 Ford 6.0L starter for the ZF 6-speed. You will not need to grind your transmission bell housing but will need the correct starter for this application.
FORD AUTOMATIC TRANSMISSIONS
4R100: This is what your truck has now if it is an automatic. It is a 4-speed transmission. If you are planning on doing a lot of heavy pulling or adding a lot of performance upgrades to your engine, you may want to have your transmission built with aftermarket parts. We recommend that you have performance upgrades done to this transmission if you will be doing heavy towing or making performance upgrades to the Cummins engine. We have two styles of adapter plates available for the diesel version of the 4R100: One for the 1989-2002 Cummins 5.9L, the other to the 2003-2009 Cummins 5.9L and 6.7L Common Rail engines. If you buy yourself a Ford 6.0L diesel starter, you can use the adapter plate that does not require the grinder job on the transmission. This adapter plate uses the stock Dodge Cummins flexplate and torque converter adapters. The adapter plate has to tilt the transmission just 2½ degrees to accommodate the starter without grinding the transmission or starter (although there is a very insignificant rib that needs just a touch of grinding just behind the starter; this small amount of grinding shouldn’t affect any core value of your case and it most certainly will not affect the structural integrity either).
If you have a CumminsCommon Rail or just want to use the Cummins starter, you will need to grind the bell housing for starter clearance.
INFORMATION ON PARTS IN OUR KITS
ADAPTER PLATES
The adapter plates for automatic transmissions require our torque converter adapters and use the Dodge flex plate. Manual transmissions require the appropriate Dodge Cummins flywheel.
Our adapter plates are built out of aircraft grade (6061) aluminum. This adapter replaces the existing adapter on the Cummins Engine, making a factory quality connection between the engine and the Ford transmission.
ENGINE MOUNTS
Our engine mounts are pre-drilled to accommodate for the stock engine fan (recommended). Because the Cummins engines are longer, your transmission and transmission cross member must be moved back about 1.5". Automatic transmission equipped trucks already have the holes in the frame to accommodate this move. The engine mounts are an excellent design with a bolt going all the way through the polyurethane isolator, instead of relying on rubber and weak interlocking tabs to secure them to the frame cross member.
In some cases the front drive shaft on four-wheel drives will stretch enough to reach the front differential.
SENSOR ADAPTERS
Our bushing kits include adapters to put your Ford gauge sending units into the Cummins engine.
ALTERNATOR MOUNT
We offer an alternator mount that allows you to use the 7.3 alternator. 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. Common Rail applications do not need the external regulator. We also offer a Dodge Cummins one wire alternator, simplifing the wiring harness and installation.
EXHAUST MANIFOLDS
Our conversion friendly manifolds work much better in the conversion for the 12-valve and 98.5-02 24-valve engines. These manifolds place the turbo in a better place for a/c component clearance than the stock variety, and also make exhaust and turbo oil drain connections easier as well. The conversion friendly manifolds improve air flow over stock and are 2-piece to prevent cracking.
12-VALVE ENGINES
When using a 12-valve engine for your conversion with one of our manifolds it is required that the housing of the turbo be re-oriented so oil feed and drain are vertical. Once the housing is re-oriented, the waste gate actuator will interfere with the engine block. To remedy this issue, we offer a conversion friendly waste gate actuator kit (DCS Part Number 1077) to fit the H1C and HX35 Turbos that came factory on the 12-Valve engines.
24-VALVE ENGINES
When using a 24-Valve engine for your conversion with one of our manifolds we recommend upgrading to a 2003-2004 Common Rail or similar style turbo . Due to the design of the waste gate actuator on the stock 24-Valve turbo it makes it difficult for the housing to be re-oriented. Using a 2003-2004 Common Rail turbo alleviates this issue.
EXHAUST RELATED PARTS
Along with replacement manifold gaskets, hardware, and turbo mounting studs, we also offer a flexible turbo drain tube that connects to the stock hose and elbow that is left in your engine block when the stock drain tube is removed. The flexible drain tube makes for an easy connection to the re-oriented turbo housing.
TACH FUNCTIONALITY
In order to retain factory tachometer function, we recommend using the Swaphelper.com Tach Helper. The Swaphelper.com Tach Helper is an electronic signal conditioning device. By utilizing the OEM Dodge Cummins tachometer sensor, whether cam or crankshaft position respectively, the Swaphelper.com Tach Helper then provides the correct signal to the receiving truck’s ECM. Not only does the tachometer function properly; any other function of the truck that is dependent upon the tachometer signal also functions as it should. Not all, but the late model trucks require tachometer for cruise control, alternator charging function, and more. When you use the DCS wire harness modification service the Swaphelper.com Tach Helper will be plug & play for your convenience.
It is not necessary to buy a diesel instrument cluster for your truck.
TRANSMISSION CONTROLLER
We highly recommend the US Shift Quick 4 transmission control module.See our Automatic Transmission Controller article for more information.
AIR FILTER KIT
Our air filter kit includes a cone style air filter; pipe, and hose to connect to your turbocharger. We offer two styles of air filter kits. The kit the 7.3L liter truck will most likely use DCS SKU 1942. 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, and allows you to keep the degas (radiator fill tank) in its stock location.
The DCS SKU 1943 positions the air filter between the passenger side battery and the radiator. This is especially the kit to use if you are using a Ford 6.0L diesel radiator and a common rail style turbo.
A/C Line
The complete A/C line, SKU 2178, connects to a 1994-2005 Dodge compressor. All you have to do is bolt the line to the drier and condensor, and refill the system. It's that simple!SOME OTHER PARTS YOU WILL NEED TO GET ON YOUR OWN
Even if you buy everything we sell for this conversion, 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 parts can be a good start). Automatic transmission equipped trucks will require a throttle position sensor. Depending on the year and transmission your Cummins engine had on it originally, you may need to purchase a throttle position sensor, or look into other options. All 24-Valve engines already have a throttle position sensor that can be used for the transmission controller.
Sometimes customers buy engines out of industrial applications. These engines may not have the correct brackets for conversion-friendly accessories.
See Cummins Engine Information for more information.
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 Conversion Specialists® is not affiliated with Cummins, Ford, or Dodge. Our use of these and other registered trademarks is for descriptive purposes only.
Diesel Conversion Specialists®
www.dieselconversion.com
320.440.2900