78 Ford F350 Isuzu 6BD1T
 

Before I got bogged down with other projects, I agreed to help my friend do some work to his truck, getting it ready for being a daily driver.

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It's a 1978 Ford F350 that he bought a couple years back with an Isuzu 6BD1T already installed. He daily drove it for a while, and it worked pretty well, but had a lot of little issues caused by neglect and some shoddy craftsmanship on the conversion.

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Initially, the plan was to replace the bad radiator, and fix the power steering, but we all know how that goes...

The power steering was a very badly scabbed together bracket using the Ford pump, and had a large notch torched out of the frame to barely clear the filler neck, which was mostly sideways, and without enough room to actually get the cap on. There had apparently been other iterations of the bracket, as two of the bolts were broke off in the block that didn't line up with anything on this version.

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I extracted the broken bolts, and fabricated a bracket for the Saginaw pump that I had used on my Jeep out of some 1/2" steel plate that I had on hand. It shouldn't have any issues coming apart or breaking bolts!

You can also see the torched frame in this picture...:argh:

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In front of the radiator was actually a pretty nice transmission cooler, which unfortunately was connected with a hardware store nightmare of plumbing fittings and tubing. The bottom radiator connection is on the opposite side from the outlet on the engine, and it utilized a long flexible hose spliced together, and loosely slung under the pulleys to cross over. The heater was also terrible and would barely get warm. I'm going to flush the core, but I found the likely culprit as both the heater lines come from the exact same place in the water neck, with no pressure differential to create flow. I'm still working on the plumbing, and don't have any good pictures of this yet.

Another thing we noticed about the truck, was that it only seemed to build boost at the governor, and smoked like crazy on the bottom end without having much power. The EGTs never climbed above around 450*, even while climbing a pass with a camper on the back. The first very noticeable problem 'interesting' charge pipe that necked way down right off the turbo for the bend over the engine, and was connected with crumbling couplers. The next problem being the exhaust, which comes off the turbo in what looks like 2.5". Then after several feet splits into much smaller dual exhaust to connect to the stock exhaust system. The thermocouple was WAY down in this Y! :argh: (a lot of this)

When I disconnected the charge tube, I noticed that the compressor housing was loose, freely clunking from side to side, but the bolts were tight. After removing the housing, I found that it appeared to be missing an o-ring or gasket to bring it into proper tolerance. The turbo otherwise seems to be in good shape with no noticeable play or wear. By the tag, I would guess that it has very low operating hours since rebuild. I ordered appropriate o-rings, but lacking a groove, they didn't fit, so I made a gasket and used some copper RTV to be sure it was secure. It's nice and tight now!

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The air filter was questionable, but it should have plenty of flow now with the BHAF that he bought!

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There's still a lot of work to do to the wiring, brake lines, exhaust, gauges, and just a ton of little bits and pieces, but it sounds a lot worse than it actually is. I've contemplated fixing the frame, but it's ahead of the suspension mounts, and would be a bear to get to with the engine mounted. Another thought has been to drop the engine and C6 transmission into a truck in better shape, probably a 4x4, but his budget is very limited.

Interesting conversion. It is an engine I've considered previously since it is very similar in size (and power potential) to a VE Cummins 6BT.

I would be be looking at a 4wd and manual trans (w/OD) conversion. Probably one step at a time to keep costs manageable.

hi good project hows the project going?

Mostly waiting on parts and looking for some right now. He has the rest of the intake parts ordered.

The major challenges of the moment are figuring out what to do about the coolant bypass hose, and the hose between the block and road draft breather assembly. Most parts are available being the same as the ones used on the 4BD1T, but these are different. The bypass hose is a really tight greater than 90* bend, and the breather hose has different size ends, and multiple bends in a short run. I haven't found any source for 6BD1 specific parts yet other than whatever is posted on ebay...

We deal with non-OE engine plumbing at work all the time. Make up the complicated stuff with threaded fittings, or soldered copper. Then connect hoses to that.

Holly Smokes!! Your not gonna believe it but I have that exact truck!! (except for the Xmsn, I'm running a Allison auto) :jump: Here I thought I was all alone!! Do you have any history on it?

And I thought stuffing a MF engine in my 87 was gonna be a bitch .... WOW...
Rotor407, Yours is a clean install ... did you do it ?

Wish I could claim it but the story I was told from the second owner was that there was a motor coach company in Washington called Beaverton motor coaches that would take your new pickup and custom build it to match and handle their custom 5th wheels. Unfortunately the trailer was sold before I got the truck. I would love more information. Ive been searching 2 years now and the 78 above is the closest iv seen to mine.

Rotor407 - Wow, that's a gorgeous truck!

This conversion isn't nearly as clean, and doesn't have the trick interior. My friend bought it from a guy in Port Angeles a few years ago. I don't think the guy had it for very long, and I'm not sure about the history before him. I have heard that there are a few running around here in WA though.

Where are you located?

Thanks, you've come along way on your friends!! I was lucky, less than 100000 miles and well cared for. I'm in Clarkston WA Ive heard rumor of a few around but never seen another and the problem is ,as I'm sure you've found, is PARTS and data. I have the original service manuals but I'm new to diesels.

WELL I'LL be .. I'm in Tacoma y'all ... maybe we can have a bomb party @ my place .. I have a huge front yard .. 4' BBQ grill .. more than engouh room for trucks here ..lol

Rotor407 - Can you post some more pictures of your engine?

I'm specifically looking for something that shows how you have the heater hoses and bypass connected at the water neck and water pump. Of course more pictures are always awesome!
Thanks!

Redveloce- sorry for taking so long, my job takes me around the world. So here are the latest pics their not great but i hope they help. Bomb party sounds great! Let me know if there is anything more i can do. Good luck!!

No worries, I appreciate it!

We're making good progress. Just on Wednesday we finished the power steering plumbing, pressure side of the turbo plumbing, coolant lines on the engine (radiator not installed yet), crankcase vent, fixed the rusted out front brake line, thermocouple installed, new boost sensor installed, and finished fabricating a new intake manifold coupler adapter.

The portable garage is on dirt, so the next step is to pull it forward onto the concrete, then drain the oil and pull the pan. The very front of the pan rubs the crossmember, and it's very close to doing a self oil change. My welded buddy is going to TIG weld a half pipe into the front of the pan to clear the crossmember.

While I'm under it, I'm going to pull the turbo oil supply fitting, which is just a barb on the passenger rear of the block, and replace it with a tee for the oil pressure sensor, and a real pressure hose. The oil supply hose is just clamped to a barb on each end. No wonder it's oily as hell... Then I'm going to cut off the tiny stock Ford exhaust, and build a simple 3" system that exits behind the cab out of stuff I have laying around.

After that it's just mostly reassembly, plumbing up the radiator and transmission cooler, running sensor lines into the cab, and some cleanup before moving into the cab to figure out why the Ford gauges don't work...

It should be almost there by the end of the weekend. :jump:

Mine had the stock ford exhaust as well, never would boost more than 5 psi, so I put in 3" straight pipe out in front of the right rear. Would have gone 4" but my bender maxed out. My boost gauge only goes to 15 psi and I peg it all day long. As for the oil pan my rubs as well so post some picks of your fix! I need to do the same. Good luck and keep up the good work :c:

We lifted the engine as far as it will go, and it turns out that we can't get the pan out without pulling the engine. After cleaning off the grease and dirt, I could see that the plate that was used to box in the crossmember sticks up about 1/4" higher than the crossmember. I think I can get in there with a cutoff wheel. Removing that extra material should make enough room, but I may also space the engine mounts up 1/4" to be sure.

Here's a picture of where the oil pan rubs. This was before cleaning, so it's hard to see how the plate sticks up.

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Well, it's been slow going, but we're still making progress. I found a bunch of the wiring melted out of the dash and some really bad hacks to get around it a while back, so I've been working on sorting that out. I think I have it mostly figured out, but I'd like to replace the old style externally regulated alternator with a newer internally regulated NPR unit to do away with a lot of the complexity. Right now I'm looking for one of those locally, but may end up having to order something.

Almost there. It's back out of the pop up garage, all of the grime and growth blasted off, and I just need to replace the transmission cooler, and tie up some wiring.

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Hey guys, sorry to dig up an old thread, but I came across this in searching for Isuzu 6BD1 stuff. I too have an old Ford w/ this engine in it (mines natural, although will be turbo'd soon). I'm from OH & my Dad did quite a few Isuzu conversions back in the 70s & 80s. I have a '76 F250 Highboy that he did for a customer in '81. The guy stopped by the shop a few years ago & offered it to me- which I couldn't turn down.


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Oh man, that's awesome! Can you post some pictures of the engine, and maybe clearance between the engine and drivetrain?

My engine bay isn't anything to brag about (yet). The truck was used for farming it's whole life & only the outside repainted a few years back. My plan is to do a frame off & make it look nice, but that will be over the next couple years more than likely.

What do you mean by clearance between engine & drivetrain?

My friend's truck is a two wheel drive. We've been trying to figure out how well everything would fit, oil pan clearance and such, with a 4x4 front axle and suspension.

Mine is a stock height (actually below slightly as it's sagged from years of use) F250 Highboy, which means low pinion front axle & a little more height than a '77-79 F250. It has a divorced NP203 (yes 203) so the front shaft is pretty long. It all fits with the tightest piece getting exhaust to flow thru & clear front driveshaft (manifold is on driver's side on the Isuzu). I think you should be fine even at stock height, but especially if using a divorced T-case & a small amount of lift.

When I get a chance I'll take some pictures & post.

Hi there.

I hope some of you guys still have your trucks and are working on them. I have 67 f250 with 6bd1. Rebuilding it completely. It would be nice to share info. Name Is Rado

6bd1 76 econoline 4x4
 

OK , so I'm new on the bombers site but have been around trucks and equipment all my life ...
I came across this thread while searching for info on the 6BD1 Isuzu engines and swaps . I have done many swaps over the years and have had many different vehicles so that's not an issue I'm a diesel tech at a Volvo/Mack dealer for the past 30 years .

I am looking for info pertaining to swapping or installing a Allison transmission behind one of these engines in a Ford f350 believe the truck is a 71 or so 2 wd . It currently has a 4 speed with a 3 speed brownie and a 2 speed rear end . regular cab with a 14 or 16 foot workmen flatbed . The truck is owned of my long time friends his father built it when we were kids way back when we were in grade school .Terry's father past away around the end of our high school years .Terry has kept and been driving the truck but now he is starting to have old age issues as we all do and would like to convert it over to a automatic trans as he is no longer able to drive it with the manual trans .

Not sure if anyone has done it or not but my thoughts have been to see if anyone has installed one of the newer Allison transmissions from behind the Duramax engines ?
or what other good heavy duty automatic trans suggestions we come up with and a place to source the parts needed ?? If I knew what to tell him to purchase he would be all over it as he loves this old truck .

Any help would be greatly appreciated thanks Merril "motorhead540"

Need to find an adapter for a Ford C6 transmission to a Isuzu 6bd1 engine, anyone have any ideas. It currently has an adapter for a turbo 400 out of a 1981 Gmc.