2003-2007 Ford 6.0L Diesel

INFORMATION FOR ALL 6.0L MODELS

The Ford ® Super Duty ® 6.0L trucks are great candidates 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.

When you buy Diesel Conversions ® parts we include installation instructions. DCS can do the bulk of the wiring work for you by sending in your wiring harnesses to be modified.

 

TRANSMISSIONS

6.0L AUTOMATICS

5R110-  These transmissions work very well in the conversion.  The advantages of using the Ford factory TCM is that you keep the tow/haul functions, retain your factory diagnostics with regard to the transmission, and the stock shift quality adaptive function is retained, and no additional wiring. We recommend our tuning services for the Ford TCM to assure proper transmission operation and to get the most from your conversion. Be certain to complete your conversion, per our instruction manual, before driving your truck. A service fee will apply for the tuning support, plus an SCT or Hp tuner will also be necessary (DCS is an Authorized Dealer).

Data logs recorded by the customer are required for our Tuning Technicians to tune your transmission to its fullest potential when mated with a Cummins engine. The data logs also allow the Tuning Technicians to confirm proper installation and all needed signals are present.

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.

   

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

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.  The engine mounts are slotted to allow for front-to-rear adjustment.

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.

It is necessary for you to make sure you will still have enough slip in the joint when your rear suspension is compressed. Shortening of your rear driveshaft may be required. In most cases the front drive shaft on four-wheel drives will stretch enough to reach the front differential.

SENSOR ADAPTERS

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 on your Cummins engine. The advantage of using this alternator is that your indicator light will still work as it should if your charging system should fail.

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 make exhaust and turbo oil drain connections easier. 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 3048) 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 using our wastegate actuator and bracket (SKU 2385) in conjunction with the Turbo exhaust adapter (SKU 1695).  Using a 2003-2004 common rail turbo is another option.  If you choose a common rail turbo you won't need a wastegate actuator mentioned above, and would want to use our complete exhaust downpipe with flange (SKU 2164).

EXHAUST RELATED PARTS

Along with replacement manifold gaskets, hardware, and turbo mounting studs, we also offer a flexible turbo drain tube. The flexible drain tube makes for an easy connection to the re-oriented turbo housing.

TACH KIT

In order to retain factory tachometer function, DCS utilizes the SWAPHELPER. The SWAPHELPER is an electronic signal conditioning device. By utilizing the OEM Dodge Cummins tachometer sensor, whether cam or crankshaft position respectively, the SWAPHELPER 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 will be plug & play for your convenience.

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 cone style air filter, steel elbow, and a hose to connect to your turbocharger. We offer two styles of air filter kits that work well in these trucks.

The DCS Part #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 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 Line

The complete A/C line connects to a 1994-2005 Dodge compressor.  All you have to do is bolt the line to the drier and condenser, & refill the system.  It's that simple!

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 our comprehensive kits.

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:

Depending on your application, you may also need 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.

Industrial Engines

Sometimes customers buy engines out of industrial applications. These engines do not have the correct brackets for conversion friendly accessories. See the Cummins Engine Information page 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 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

(320)440.2900

Knowledgebase Topic:

Conversion Overviews

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