The 4BTA is a great engine for any 1/2 ton swap project. The suspension will handle the extra weight but I would upgrade to hydroboost brake (my experience). They help alot with the extra weight up front.
You can even drop one in a dakota or S10 with the right suspension upgrade. More work though adding the suspension and working in tighter quarters and a lot more work if you are working with a 4x4.
A turned up intercooled 4BTA gets you the same H.P. and torque as a 1st generation Dodge 6BTA; Again, my experience. I had a one ton 1993 6BTA before I made my half ton
4BTA. Expect 25-28 mpg in a 1/2 ton when you are not loaded down and about 15-17 mpg when hauling about 7,000#. The 4BT with the VE injection pump is really easy to turn up and double the H.P. and torque without paying a penny to do it. Another real plus. The only down side compared to newer diesels is that you are stuck with those settings until you climb under the hood and change them with some wrenches and screwdrivers. Not a bad trade-off if you are on a budget. It takes about 1/2 hour and some wrenches for me to change from stock 105 h.p 283 ft. lbs. to 180-190 h.p. and 383-400 ft. lbs.
You can go up to about 300 H.P. on this engine with twin turbos. Guys have used the
HY35W that has a smaller turbine cross section and combined it with larger turbos for the series setup. Expect something to rapidly show itself as a weak link if you do this. 1/2 ton truck drivetrains won't take this large of a torque in the lower RPM range for very long.
I also make bio-diesel if anyone needs more ideas on that. The 4BT is tolerant to fuel grade changes and thus lends itself well to bio-diesel useage. You just need to be sure you start off with high grade race rated gasoline fuel lines for bio-diesel exposure.

Questions About Conversion
 

Hi, I just joined this site, I'm wanting to do this very same conversion, 99 F150 4X4 extended cab short bed, 5.4, 4R70W auto, the 5.4 is shot, can you give me any advise on this conversion, I've been researching it for a year or more and want to do it real bad. I've read that the transfercase support, crossmember, is a real headache, I would appreciate any advise, help or insight. Thank You, Doug

that 7.3 b alittle too heavy for a 1/2 ton go with the 3.9

A newer 04+ F150 with a commonrail and a big lift would be straight up awesome!:U:

Thanks for the input, but I already have the 99 and am on a budget, my main objective is economy and the ability to burn WVO and biodiesel, so a cummins 3.9 is what I'm leaning toward.

5.4 to 7.3 swap
 

Hi i have a 2000 F-250 5.4l but the motor is blown. I was wondering what i would have to change to put a 7.3 powerstroke in it?

go with a 4BTA rather than the 7.3PS, read through this thread and you will find that the 7.3 is both lacking in TQ and is overweight compared to the 4BTA... and for the prices it would cost in upgrades i see the 4BTA as a better option.

Try and find a wrecked diesel truck of teh same year the start swapping parts. Or if your heart is not dead set on the 7.3 look into dropping a cummins in it. Alot easier to get it running. a 98 or older 5.9 cummins only needs 3 wires to run.

For teh original poster, I think anything over a stock 4bt cummins will destroy your driveline fast. Ando also you wont gain any payload or towing capacity with a diesel swap because you ares still running a 1/2 ton frame and axles.

hey guys i just signed up for the site because this thread is perfect for what im trying to do, i have a 1994 F150 with a 4.9 and something happen the computer because i have no radio, no speedometer,no odometer, and the shift points for the trans are all screwed up. so i figured im young im mechanically inclined so why not put a diesel in it. i can get my hands on a 7.3 for practically nothing and i was going to do it, but i wanted to do some last minute research and thank god i did. what do you think i should do powertrain wise?

i have a 2000 ford f150 5.4L V8 4x4 single cab long bed. iv been wanting to put a 7.3 in for a while now. i was wondering how possible it would be. i'm already upgrading the front suspension. im converting it to a solid axle(Dana 44) from a 78 bronco. if needed ill box in the frame if not already and add extra cross members. i was planning on buying a donor truck thats running and pull the motor out with transmission and install in my truck. if im missing anything here let me know and some helpful tips would be great. thank