How To Swap a Ford 7.3L Power Stroke V-8 with a 5.9L Cummins I-6 and Allison 1000 Transmission Photo Gallery
Big-3 Blend: Part 1 - How to Combine Ford’s Super Duty With a Cummins/Allison Powertrain
Bruce W. Smith –
Oct 7, 2016
Photo 1/16 | Ford Cummins Transmission Swap
Photo 2/16 | Ford Cummins Swap
Photo 3/16 | Cummins F 250 Diesel
Photo 4/16 | DeStroked Cummins | Used Cummins engines are plentiful. Look for one with low miles and complete with the wiring harness. We picked this one up for $3,500, and it’s certified to be in good running condition.
Photo 5/16 | DeStroked Flexplate Adapter | In order to make the Allison 1000 six-speed automatic transmission work with the 24-valve, 5.9L Cummins engine, the DeStroked conversion kit includes this custom-designed flexplate, so the two mate up perfectly.
Photo 6/16 | DeStroked Allison Adapter | This CNC-machined aluminum plate adapts our engine to a transmission. The adapter has to be used with the special flexplate.
Photo 7/16 | Destroked Used Allison Trans | Here’s our used Allison 1000 from an ’07 Chevrolet Silverado 2500HD. The transmission can be used as is, but we’re going to have it rebuilt and beefed up a little to handle the higher power and torque output we’re expecting from the Cummins.
Photo 8/16 | DeStroked Allison Wiring Harness | DeStroked makes the integration between Ford’s wiring and the later-model, six-speed Allisons easy with this standalone wiring harness and controller. The controller lets you define shift points, torque-converter lockups, and shift firmness. It also has tunable torque input, throttle-position-sensor calibration, engine-rpm calibration, Tow/Haul mode, and overdrive cancel.
Photo 9/16 | Destroked BD Exhaust Manifold | One problem many first-time conversion guys figure out right away is the Cummins turbocharger interferes with the Ford air-conditioning system. That’s where BD Diesel Performance’s “Pulse” exhaust manifold (PN BD 1045987) comes in handy, as it relocates the turbo so it clears the Super Duty’s A/C components.
Photo 10/16 | Destroked Timing Sensor | This special DeStroked kit allows the Cummins’ rpm to be displayed correctly on the truck’s stock tachometer. The hub and tone ring bolt to the front of the crankshaft damper.
Photo 11/16 | Destroked Fleece Coolant Bypass | Cummins I-6 engines are known to have some cooling issues with the rear two cylinders. We’re eliminating those concerns by installing this Fleece Coolant Bypass kit.
Photo 12/16 | Destroked TCase Adapter | An added level of adaptation in this swap is mating our Ford Super Duty’s transfer case to the Allison automatic transmission’s tailshaft. DeStroked has that covered with this adapter kit, which includes a new input shaft for the transfer case, and a tone ring that goes on the front of the new input shaft. The sensor that reads it is installed in the transmission’s tailhousing. This setup gives complete, stock-like shift control in either 4 high or 4 low, without needing a separate ECM calibration to operate the transmission.
Photo 13/16 | Destroked Battery Tray | One task that is typically overlooked is mounting the batteries. DeStroked has a cool battery tray that’s milled from billet aluminum to give the finished swap a touch of class.
Photo 14/16 | Destroked Remote Oil Filter Kit | DeStroked’s remote oil filter kit helps create a lot more room for the Cummins engine to fit in the Ford’s engine compartment.
Photo 15/16 | Destroked Coolant Hoses | Another item in the conversion package that helps makes the swap easier is this lower radiator hose kit, which eliminates the need for running to the parts house to track down the correct fittings and hoses.
Photo 16/16 | Destroked Motor Mounts | Trying to figure out where to place a 5.9L Cummins engine in an ’01 Ford F-250’s frame would be a real headache if it weren’t for these custom motor mounts. They are labeled and ready to bolt into ’99-to-’07 Super Dutys.