Hello everyone, I am heavily debating swapping a 2003-2004.25 5.9 in my 2003 6.0 Ford Excursion. I have spent a lot of time the past few days reading about the engine and swap involvement but I'm still a little confused in areas.


First my 6.0 is currently around 950 ft lbs of torque and would like the 5.9 to be similar in power but not much more since I'm near the limit of my stock 5r110w. From what I have read and been told by a 5.9 loving mechanic, that it's an easily reachable daily driving and towing number, if it was staying in a dodge how expensive parts wise would it be tuner + turbo? Not opposed to going higher but it will have to wait until my tranny dies and needs replacing or being built.

Since the engine will be out what all if any upgrades/changes should I make. Headstuds, fuel rail line, water pump, gaskets, etc? Or should I just use it as a core to get a reman one?

I plan on buying the whole vehicle for the swap and then selling it (- engine and everything else I need) do you guys recommend I just buy a complete engine instead? I found a few trucks locally one of them has listed that it's leaking oil from the head gasket your opinions on this?

Does anyone know of a good shop in the Houston Texas area to do the swap? I have family in San Antonio so that would be the next best place.

I know that I'm forgetting stuff right now....

Thanks in advance for your help.

 

You will need head studs going that high of a HP. Since you have tuned your 6.0 you already have an idea of price. Tuner, injectors, and turbo/s...you will fly past the 6.0's powerlevel in no time. You will be a lot of money out of pocket but you will be there.

 

The recipe I found doesn't say Headstuds but I figure might as well since the engine is out. Can 5.9 do one at a time studs or should I pull the head and have it machined?

500 Horsepower is about 950lbs of torque right?

AFE or S&B Cold Air Intake (Wonder if I can make my 6.0 filter work since it's good till 550hp and holds 3lbs of dirt)
4" Turbo Back Exhaust (Have that just need downpipe)
64mm Turbo
Exhaust Manifold
60 HP Injector Nozzles
Smarty S-06 POD
Boost Fooler
FASS 100 GPH Fuel Pump (Probably do the 6.7 power stroke pump + sump)
Industrial Injection Bag-of-Parts CP3 Modification
ISSPRO or AutoMeter Factory Match Gauges (Currently have Edge CTS2)

 

In a cummins 500hp is over 1000ftlbs. From what i have seen they usually make 2.3 times more torque than hp. Yes you can stud one at a time. When you get in the 45 to 50psi range you need studs.

 

Okay I need to do more research than I thought I saw a dyno graph that put a 2006 5.9 (is the block the same and just different programming?) at 510hp and 960lbs of torque.

 

In your situation I would efi live it and a turbo and call it a day. Unless you are looking for a beast.

 

EFI live is only supported on the 06+ Cummins from what I have read and I'm looking at the 03-04.25 because they are a simpler swap. I'm not looking for crazy power but I am looking for quite a bit IMO.