1992 F250 4x4 Cummins Conversion
#1
01-31-2010, 07:23 PM
1992 F250 4x4 Cummins Conversion
Here are some pictures and info on my Cummins swap.
What I started with, stock 1992 Ford F250 XLT with a 460efi and E4OD
The donor truck: 91.5 Dodge Cummins, one owner, 250k, got it from a guy I worked with for $500!!!!
Pulled it all out in one shot
Welding up my shackle reversal front hanger
Getting ready to put the Dana 60 in. No more POS TTB!!!
Front hanger installed with "V" code Super Duty front springs
My rear shackle flip brackets all welded up
Brackets welded onto the frame
Got the worst of the suspension work out of the way, got the clip and core support off, time for some fun!!!
Got the 460 and E4OD out of the way
Fitting the Cummins and A518 in place
Got the core support back on, time to fab up some mounts
What I started with, stock 1992 Ford F250 XLT with a 460efi and E4OD
The donor truck: 91.5 Dodge Cummins, one owner, 250k, got it from a guy I worked with for $500!!!!
Pulled it all out in one shot
Welding up my shackle reversal front hanger
Getting ready to put the Dana 60 in. No more POS TTB!!!
Front hanger installed with "V" code Super Duty front springs
My rear shackle flip brackets all welded up
Brackets welded onto the frame
Got the worst of the suspension work out of the way, got the clip and core support off, time for some fun!!!
Got the 460 and E4OD out of the way
Fitting the Cummins and A518 in place
Got the core support back on, time to fab up some mounts
#3
01-31-2010, 07:57 PM
Engine mounts, used 1/2" thick angle iron and plate and then the factory Cummins bushings
Lucked out and just had to drill some new holes and could reuse the factory Dodge trans crossmember
Got the nose clip back together. Didn't get any pics of the brackets I made to fit the Dodge intercooler, may have to pull the grill back off and take some later. Straight piped, side dump with 5" chrome tip
Used Ford rear axle spring plates with new holes drilled and shock tabs welded to them and then a high steer arm with a factory F350 drag link.
I used the stock in tank electric pumps with a Holley fuel pressure regulator/w return bypass to cut the line pressure down to 7psi
Fab'd up brackets to fit the Dodge radiator. Managed to get the Cummins throttle cable to hook to the Ford pedal and hit WOT. Same with shifter cable, modified the linkage on the A518 to fit the Ford cable, runs through all the gears, put the OD lock out on a toggle.
Wired the grid heaters to a push button on the dash
Patched the hole where the T-case shifter came through, still need to patch the hole in the carpet or get new carpet.
How she looks almost finished, painted the wheels black and put my canopy back on
Major things left to do are get pinion degree shims and align it, get a trans cooler and run the lines, figure out why the alternator isn't charging and get a front driveline built. Also before next summer, figure out how to mix and match the AC system to work, at the moment I just deleted it.
Lucked out and just had to drill some new holes and could reuse the factory Dodge trans crossmember
Got the nose clip back together. Didn't get any pics of the brackets I made to fit the Dodge intercooler, may have to pull the grill back off and take some later. Straight piped, side dump with 5" chrome tip
Used Ford rear axle spring plates with new holes drilled and shock tabs welded to them and then a high steer arm with a factory F350 drag link.
I used the stock in tank electric pumps with a Holley fuel pressure regulator/w return bypass to cut the line pressure down to 7psi
Fab'd up brackets to fit the Dodge radiator. Managed to get the Cummins throttle cable to hook to the Ford pedal and hit WOT. Same with shifter cable, modified the linkage on the A518 to fit the Ford cable, runs through all the gears, put the OD lock out on a toggle.
Wired the grid heaters to a push button on the dash
Patched the hole where the T-case shifter came through, still need to patch the hole in the carpet or get new carpet.
How she looks almost finished, painted the wheels black and put my canopy back on
Major things left to do are get pinion degree shims and align it, get a trans cooler and run the lines, figure out why the alternator isn't charging and get a front driveline built. Also before next summer, figure out how to mix and match the AC system to work, at the moment I just deleted it.
Last edited by 92_cummins_f250; 01-31-2010 at 07:58 PM. Reason: Automerged Doublepost
Thanks for posting all those pics. 
#7
03-24-2010, 12:26 AM
#9
05-03-2010, 08:19 PM
Welcome to Diesel Bombers to start with!! 
And as for the lines, I took both the Ford and Dodge lines into a local shop that builds hydraulic lines and had them build me a new one with the Cummins pump and Ford steering box ends. I think it was like $30-40, can't remember for sure now. As for the return line, it's just low pressure power steering hose. You should start a thread with your conversion too, would like to see pics of it!
And as for the lines, I took both the Ford and Dodge lines into a local shop that builds hydraulic lines and had them build me a new one with the Cummins pump and Ford steering box ends. I think it was like $30-40, can't remember for sure now. As for the return line, it's just low pressure power steering hose. You should start a thread with your conversion too, would like to see pics of it!
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caliboy (05-05-2010)
