Information for all 6.4L models

The Ford ® Super Duty ® 6.4L truck is 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, intercooler and fan shroud can all be used as is with the Cummins engine.

When you buy Diesel Conversion Specialists’ parts we include installation instructions.  DCS can also do the bulk of the wiring work for you. Depending on the engine choosen, we offer either a new conversion harness (12V and 2003-2004 common rail) or a harness modification service (24V and 2005-2009 common rail).

*You must retain the 3 sensors located in the exhaust system*

Automatic Transmissions

5R110

These transmissions work very well in the conversion.   The advantages of using the Ford factory TCM are that you keep the tow/haul function, retain your factory diagnostics with regard to the transmission, and the shift quality adaptive learning remains functional.  The stock transmission harness is utilized with 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 $495.00 will apply for the tuning support, plus an SCT or HP Tuner will also be necessary (DCS is an Authorized Dealer).   We offer several tuning options; SCT X4, SCT Livewire TS and HP Tuners.  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 necessary signals are present.

*Note:  It is strongly suggested that you have the PCM in your truck flashed to the most recent factory firmware version.  A best-case scenario is to do so prior to converting, although your truck can still be flashed after the conversion if need be.  If you are the original owner, you should have received communications from the manufacturer regarding these updates.

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

Dodge Automatics

While many of our conversion parts will work if using the Dodge transmission, we currently do not offer any technical support for tuning these transmissions.

 

Information on parts in our kit

ADAPTER PLATE

Our adapter plates for the 6.4 Super Duty use the stock 6.4 Ford starter. No modification is required to the transmission bell housing. These adapter plates use either our custom flywheel or custom flex plate. Our 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 quality aluminum.

AUTOMATIC TRANSMISSION CONTROLLER

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

ENGINE MOUNTS

Our motor mounts are pre-drilled and slotted to accomidate either the engine driven fan (recommended) or electric driven fan. When using the Cummins engine driven fan, the rear drive shaft will need to be shortened, but 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. 

The engine mounts are an excellent design with a bolt going all the way through the polyurathane isolator, instead of relying on rubber and weak interlocking tabs to secure them to the frame cross member.

SENSOR ADAPTERS

We custom build adapters to put your Ford gauge sending units into the Cummins engine so that your stock gauges still work with the Cummins engine. This also helps get your power steering and brake system working.

ALTERNATOR MOUNT

We offer an alternator mount that allows you to use the 6.4 alternator. The advantages 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 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.

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 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.

TACHOMETER 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.

AIR FILTER

We offer an aFe POWER air filter, pipe and hose to connect to your turbocharger. The DCS part# 1943 positions the aFe POWER air filter where your factory air filter box is now. 

A/C MANIFOLD

This manifold bolts to the back of a ’94 and newer Dodge a/c pump, making the a/c plumbing less of a challenge. When installing an older Cummins (89-90ish) into the Super Duty we recommend using the 94 or newer Dodge A/C pump and bracket. The newer pump is shorter and the lines are attached differently than on the older models. It is necessary to have adapters welded to your Ford A/C lines so that you can have hoses crimped together with the A/C manifold that we send. Keep your Ford high pressure switch.

RADIATOR HOSE KIT

This 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. This also includes the fill tank hose.

PEDAL BRACKET KIT

If your truck has adjustable pedals, or if it is equipped with an automatic transmission, you may want to buy our pedal bracket kit. These bolt onto your existing Ford pedal, enabling you to pull a Cummins throttle cable. Our pedal bracket kit is necessary for cruise control to function with the 5R110 transmission.  Refer to the throttle pedal identification article to identify the pedal style you have, then we can get you the kit you need.

WIRING HARNESS SERVICES

Depending on the conversion engine you will be using, DCS offers either a new 6.4 engine harness or a harness modification service. Please see various options available in our Kit Builder for your specific project.

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). 
A Dodge throttle cable, and a Ford gas powered truck’s cruise servo. When you order parts, we can additional detail.

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 pedal bracket kits. These are especially helpful if you have adjustable pedals and want to keep that feature. Refer to the throttle pedal identification article to identify the pedal style you have, then we can get you the kit you need.

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.  

 

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

320.440.2900

 

Knowledgebase Topic:
Make of Truck:
Ford