2008-2010 Ford 6.4L Diesel
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.
You are not on your own when choosing to do a conversion with DCS. Installation instructions are included with your parts purchase. Technical support is also available either through phone or email. DCS can also do the bulk of the wiring work for you. Depending on the engine chosen, 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*
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. An SCT or HP Tuner will be necessary for our tuning service (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 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. If possible, have your truck flashed prior to the conversion, many Ford dealers are hesitant to flash a converted truck. 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.
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
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.
Our motor mounts are pre-drilled and slotted to accommodate 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, however the front drive shaft on four-wheel drives will extend 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 polyurethane isolator, instead of relying on rubber and weak interlocking tabs to secure them to the frame cross member.
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.
We offer an alternator mount that allows you to use the 6.4 alternator. The advantage of using this alternator is that your indicator light will still work as it should if your charging system should fail.
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 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.
We offer an aFe POWER air filter, pipe and hose to connect to your turbocharger. The DCS SKU 1943 positions the aFe POWER air filter where your factory air filter box is now.
DCS offers a bolt-on custom machined AC manifold and ready to install low-side AC line, (SKU 2476). The AC manifold connects to a 1994 – 2005 Dodge A/C compressor. The DCS low-side AC line and the stock Ford high-side AC line connect to the manifold and the truck’s existing system. The stock Ford high pressure switch is also utilized.
RADIATOR HOSE KIT
This kit includes the radiator and heater hoses that work well in the conversion and include a specially bent aluminized steel tube, 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 provide 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.
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