96 F-250 Common Rail?
 

I have a buddy with a 96 F-250, and he was trying to sell it to get a common rail dodge, but has decided that he just loves his 96 ford too much, so if we can find the motor and trans, we are gonna put probably an 04 Cummins with the NV5600 in his truck. Im aware of the extra difficulty of using a common rail instead of the 12 valve, but it will be a lot more unique, with more stock power. What will we have to do to make the NV5600 bolt up to his transfer case, or should we use the dodge transfer case? Anybody got any advice about any parts of the swap, unless its keep the powerstroke, ha, and unless its use a 12 valve, other than that any help would be great.

Just curious what extra difficulty you're talking about? If you're referring to "wiring", relax, it's way easy if you're using a manual trans.

I used an NV 4500 and the Ford 13-56 T-case with an adapter from Advance Adapters.

94Matt, how'd you go about getting all the wiring to mesh together like the ECM and gettin all the gauges to read properly and such?

painless wiring has a harness you can buy now that plugs into the common rail plugs on one side and the ford plugs and wiring on the other, so its completely plug and play. its bout 1100 but for someone that is much better at eletrocution the electricity, its worth it, lol

Cummins does it for you, all wiring needed to run is in the engine harness and connected to the ecm on the side of the engine. Only takes three wires to run with a manual, everything else is just how complicated you want to make it. I'm doing this now on mine, so I'll let you know if there are any snags but there are plenty of people that have done it before me and they are saying it's no big deal as well.

For gauges, I'm adapting the ford sensors to the engine. My truck does not have a tach, so I have no idea what it takes to make that work.

I'm using the ecm to control my in tank fuel pumps, just as it did the lift pump on the dodge, going to try sticking with the ford starter relay and see how well it holds up to the amp draw of the cummins starter. My truck had a gasser and my engine has the apps by the intake horn, so I had a throttle cable on both trucks. I cut up the dodge and ford cables and made one Fodge cable that has the factory pieces on both ends. You'll have to get a gasser pedal since you're starting with a powerstroke.

I still need to go rob the obd2 port off my wrecked truck to see what it's going to take to hook that up. I'd like to have it so I can run a smarty and check codes.

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The painless kit is kind of a joke unless you don't have the engine harness to begin with. It is essentially identical to the factory harness in my opinion. I looked pretty close at doing that until finding out what it really takes to wire one of these up. The wiring difficulty is blown way out of proportion, and really isn't much different than wiring up a 12 valve.

Well thanks for all that info. Pretty much all of it makes sense except for your Fodge throttle cable. My mechanical knowledge and skills aren't nearly what some of ya'll's are, but if I'm not mistaken....on the common rails and even VP trucks, it was my understanding that there's no throttle cable, just a TPS that senses what percentage to open up in relation to how far down you've got the pedal mashed? Am I a complete moron or did I miss something there?

Go look under your hood. There is a cable from your pedal going to the APPS mounted by your intake horn. The 03's have the same setup and I think some 04's do also, then they moved the APPS somewhere else in the engine bay after that.

You're right that the sensor controls the engine, but there is still a cable that controls the sensor:c: Powerstrokes have the sensor built into the pedal, hence no cable, and the guy will need to get a gasser pedal so he can run a cable to an APPS.

you can also give Aden at GOS performance a call, he did a swap in his PSD and has done a few more CR swaps IIRC.