1992 F150 4x4 4bt swap
 

I finally have enough parts accumulated to start building. I bought a 1992 Ford F150 Extended cab 4x4 with a 302 and a factory 5 speed. It has 3.55 gears and only 157k orig miles.
The engine is a 4BT Cummins ve pump that already has the sbf adaptor. The tag shows 2007 rebuild. Here are some pics of what I have so far the truck has been sitting sice 2004 with a cracked exhaust manifold
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Attachment 33291Attachment 33292heres a nice t19 if any one wants one
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I got real lucky and found a 1st gen 5.9 in the junk yard and kinda went crazy pulling parts I got everything you see here for 120 dollars. Including the ps/ vacuum pump
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Now I do have a few questions for some of the resident cummins guys.
1st I noticed the 5.9 has some sort of sound deadening material attached to the lifter cover. My 4bt doesn't have this. And. Seems that's where alot of the diesel clatter come from. I pulled is to try but any input is welcome

2nd I got a manifold to cut down to a center dump. Are you guys using nickel rod in a arc welder or is there a better way with a mig that I'm missing.

3rd 3200 rpm or 3500 rpm gov spring?

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I'm jealous...that's the exact swap I'm wanting to do but the wife has that idea on hold since i just swapped a 5.9 into my 3/4 ton. Be sure to keep us updated. Now I'm no expert but I'd do the 3200 spring cuz I've heard if u go too high ya have to upgrade valve springs. My question to u would be why aren't you just gonna use the manifold that's on the engine?

I wouldn't worry about the sound deadener. Many of us remove it. Loud? whatever... :rocking:

Not sure on the manifold.... can you flip the stock one? Or run a 'cobra-head' downpipe piece? Cast needs a lot of pre-heat or it will crack when welded. Hard to keep it from warping without it being mounted to something solid.

Either gov spring will give you lots of fuel over the stock 2500(?).

I'm jealous. Wish I could snag a 4BT as cheap as a 6BT... for a basic DD truck. :c:

I may use the manifold that is already on there if I can make the down pipe fit. I picked up the 6bt manifold because it was 10 dollars and I can use it as a center dump if I need to. As far as making it quiet I really like how quiet my kubota in my ranger is and would like it to be close. So I am really going to take the time to try to quiet this 4bt down. My brother has some engines that he works on in the Airforce that have been rigged for silent running, just simply by spraying a sound deadening material over the oil pan, lifter cover, valve covers, and a large portion of the block.

Fresh coat of paint today.Attachment 33246Attachment 33247
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Here is the comparison of the 4bt clutch (bottom) and the. F150 clutch top
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I was really surprised to see how clean everything was inside.
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Update. I have it on the road now as a dd. I've driven it 300 miles so far and I'm seeing 25.9 mpg. I put new tires on it 31x10.5. And I love it power is great vibrations are almost non existent and the power is smooth. I can hit 31-32 lbs of boost. And egts won't go above 1000[IMG]http://i1337.photobucket.com/albums/o673/Ethanolsen77/imagejpg6_zps993277b8.jpg[/IMG
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I ended up with a banks exhaust from a 94 idi for and I made the down pipe all mandrel bent

I have about 1700 miles on it now I'm seeing 28 mpg from Monroe wa to chelan and back to Monroe and that's going over a pretty steep pass. I finally to the ac hooked up today as well as the elec cooling fan. I went with a mercury villager fan it's huge and its 2 speed so it goes on the low speed when the ac is on and the high speed when/if the coolant reaches 200 Attachment 32594
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Wow that could very well be my next swap when my kubota/ranger is complete. Nice job!