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.
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.
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 of $450.00 will apply for the tuning support, plus a SCT tuner will also be necessary (DCS is an Authorized Dealer). We offer two different options; the SCT X4 and the SCT Livewire TS. 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. 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
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.
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. 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.
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.
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.
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. The conversion friendly manifolds improve air flow over stock and are 2-piece to prevent cracking.
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.
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 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.
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 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.
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 condensor, & 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 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.
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.
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.
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