Common Rail Engine Driven Fan Options for 99-07 Ford Trucks 

You have three choices on fans: Aftermarket electric, non-electronic-engine driven, or the stock Dodge vistronic.

It can be best to wait on deciding on what option you will use until you get the engine in the truck and see what you will end up doing with your drive shafts.

AFTERMARKET ELECTRIC

We do not recommend this option in most cases. If you live in a cooler climate or don't work your truck too hard, you may be able to get by with electric fans. Do not buy fan kits designed to replace the factory engine driven fan in stock configurations- as they are too thick to be any help to you in avoiding the transmission move back. We have heard back from many guys that used large or even 2 twin fan kits that have had cooling issues. This is because the fan cfm is not rated behind all the coolers and radiator. Electric fan manufacturers do not recommend their fans for trucks over a certain GVW.

NON-ELECTRONIC, ENGINE DRIVEN

You can use a Ford 5.4 clutch with a 99 Power Stroke, or a V-10 (smaller than the P.S.) blade on it. These blades will bolt right on. We are not sure about the durability of this combination, but it is an option. Both of these blades are smaller than the 6.0 blade so they are not as good for trucks that need superior cooling, such as a work truck or trailer puller. On 6.0 trucks use the existing radiator shroud, but throw away the engine side of the shroud on the 6.0.

The biggest drawback to this option is that cutting your rear drive shaft and placing the engine in the rear most position with our mounts is a must. This is because the 5.4 fan clutch is longer than the Dodge vistronic clutch.

The V-10 blades will fit in your 99-02 shroud, but they may be a bit too small for high ambient temperatures or heavy towing. The Power Stroke fans are too big to fit in your existing fan shroud on 99-02 trucks so you will also need to trim the blades or get a 6.0 Ford radiator (03-07), shroud, upper brackets, and fill/expansion tank. The expansion tank must mount on the driver’s side firewall where it does in the 6.0 trucks. Two pieces of flat bar bolted to the top edge where the wire loom runs work for mounting. The hose must go from the expansion tank down to the lower radiator hose or equivalent. Do not plumb this hose into the driver’s side of the block or the top of the head. You will only need one of the 3/8” hoses from the top of the radiator to the top section of the tank.

DODGE VISTRONIC

This is the original equipment, engine driven radiator fan on the ’03 and newer Cummins engines is a combination viscous/electric clutch fan.

One advantage to using this option is that when you can place the engine in the middle position (not possible in every truck) you can use the Dodge vistronic clutch, even when you can’t get others in, as it is very space efficient on the Cummins with the 6.0 blade.

When using this fan in a conversion, you will need the Cummins vistronic wire connector option in your harness build.

For 1999-2007 trucks, reuse or acquire a 6.0L fan blade. This blade is slightly smaller than the Dodge blade and will fit in a Ford 6.0l fan shroud. You can discard the part of the shroud that bolts onto the engine, unless you want to make brackets for it to be mounted to the Cummins engine. The 6.0l blade will bolt right on the Dodge fan clutch. If you don’t have the Ford blade, you can trim the Dodge blade using a set of dividers to mark the blade and cut it with an abrasive cut off wheel.

For 2008-2010 use the Cummins fan blades because they move a little more air than the Ford fan blades. Also the 6.4 diesel fan blades turn the opposite direction when compared to the Cummins fan blades.

TURBO AND EXHAUST

The common rail exhaust manifold is already conversion friendly. If you do not have one, DCS offers a high flow option. If you have a VGT turbo, you will need to purchase an aftermarket controller to retain VGT functions. Other options would be to install a 2003-2006 non VGT common rail turbo or an aftermarket turbo. DCS also offers a few options for down pipes or often times, a portion of the stock common rail downpipe can be used.

03-09 Cummins Common Rail, 5.9L/6.7L Information 

          The Cummins common rail engines are a great choice for your conversion.   They offer great power and reliability.   Engine tuning upgrades can be done electronically with several tuning service businesses existing in the US and Canada.   Full engine diagnostic capabilities are also retained.  

          There are differences in the various model years you’ll want to be aware of before sourcing an engine.   Below are some conversion related notes for your consideration.  If you are unsure if your ECM is from an automatic or manual transmission truck we can verify this if you provide us with the ESN listed on the ECM. 

2003-2004 with Manual Trans ECM:

• Original APPS (accelerator pedal position sensor) mounted under battery.
• ECM is compatible with DCS’s harness modification service and pedal module.
• Key recognition security system was optional on some models which may require a re-flash of the ECM.
• ECM and Wire harness must match.  Automatic is different than Manual transmisson wiring and ECM.

2003-2004 with Automatic Trans ECM:

• Original APPS (accelerator pedal position sensor) mounted on engine. This is retained.
• ECM is compatible with DCS’s harness modification service.
• Key recognition security system was optional on some models which may require a re-flash of the ECM.
• ECM and Wire harness must match.  Automatic is different than Manual transmission wiring and ECM.

2005:

• Both the Automatic and Manual trans are compatible, however the Manual trans ECM has been reported to be more desirable for power & tuning.
• Key recognition security system was enabled and will require a re-flash of the ECM.

2006-2009 5.9 & 6.7 Liter:

• Dodge TIPM (Totally Integrated Power Module) required for OBD port communication (On Board Diagnostics).
• ECM re-flash necessary to eliminate SKIM (Sentry Key Immobilizer Module) security function.