'97 F350 4x4 Crew '97 12V P-Pump & G56 Build thread
 

I'm not completely new to the site, I've spent time here researching before beginning my own build. I hope you all enjoy seeing what I'm putting together. This project comes after many years of dreaming, planning, & choosing what components I wanted to incorporate. I hope that this truck will serve our family for many years to come.

So here's the lowdown:
1997 F350 4x4 Crewcab 460 E4OD 235K miles - bought online as a repo from Arizona in October 2009.

1997 12V P-Pump Cummins from El Paso, TX - bought the same weekend from an Army Sargeant that just received orders for Iraq & had to put his own '77 Ford/Cummins plans on hold.

2007 G56 6-speed from one of the last 5.9 Cummins/Dodge. It had 1100 miles on it when a tree blew down & smashed it. I got everything from the adapter plate to the output shaft, complete, ready to roll!!

I had quite the adventure driving the truck from LA, CA where it was held after I 'won' the auction to get the Cummins in El Paso, & then home to Kalispell, MT.

I also sourced the G56 from a great guy in OH after selling an awesome 1st Gen Dodge Cummins out that way.

Next, for the beginnings of the build!

One BIG problem I had to get past was not having a place to do the work of swapping engine/transmission combos, nor having the equipment to do so. I have a low-ceiling regular garage at home, but this crewcab longbed won't even fit half-way in!

Huge provision #1 - A good friend leased a home 30 minutes from me with a newly built 40x60 shop w/ overhead gantry/chainhoist, 2-ton engine hoist, jacks, tools, etc. Since he doesn't do anything remotely mechanical, he said 'Come on over & use this shop to build your truck!'

So, I spent a few months assembling parts, planning, measuring, prepping the engine, etc. He lit a fire under me late August '10 when he let me know that I needed to be cleared out of the shop by October 3, '10! Whew! I spent 2 weeks of September putting in 12-18 hour days to get everything I could done before moving back to my garage at home.

So, I'll start with the gasser disassembly on September 11 up to where I am currently.

one word SWEET!!!!! i wish a truck like that would have been made from the factory!

September 14:
460 & A/T pulled out. Dropped BW4407 t/c & checked it's vitals. Looks like a fairly recent rebuild, tight chain, feels great so I think I'll use it as-is. Pulled a/t shift cable, shifter mess from steering column, & brake pedal assembly. Installed clutch & brake pedal assembly & Ford clutch m/c.

I was lucky enough to have a good friend who owned a farm and had a big shop for my first swap in as well! Thank goodness for good friends is all I can say.

Great platform and I'll be watching this one for sure!:c::c:

Just label your wires and reuse your old temp and oil sending units so your gauges work!

Its pretty straight forward.

I'm doing a 99 Super Duty next when I finish rebuilding the engine.

I need to get up north Idaho and over to Montana this next summer to see all of the Ford Cummins Conversions:jump::jump::jump:
Once again Good luck.

I say come on over! There are quite a few around the area. I guess we like doing things ourselves up this way. I'll have to post the pics of pulling my '97 project home with a friends '95 F350 Crew Cummins!

September 15-20 had a conference, so no progress on the Cummins!
It was an awesome conference, so I had excellent progress elsewhere in life!!

September 21:
Sold the E4OD, so I prepped it and all associated parts to go home with the new owner! Cash for more goodies!!
Lifted the bed off to get to fuel tanks, dropped them, cleared out all gasoline, cleaned, & reinstalled.
Cleaned, wire brushed, & primed front half of frame & undercarriage

Doing all this by myself with no extra hands to help out, I sure am grateful for the overhead hoist & the engine hoist. Especially for moving around the bed!:argh:

September 22:
Pulled a dumb move & slipped the engine off a temporary stand. Thankfully the intake horn took the hit, no other damage or impact.:s:

Cleaned more of the frame for primer.
Prepped some of the engine parts for Rustoleum Copper Hammered paint.
Prepped engine block for silver paint.

Had to have flywheel from '07 machined .004" on the hub to mate with my '97 crank. Finally got the flywheel, clutch, & G56 mated to the engine for the first time!!:yeah:

September 23:
Located correct radiator to mate w/ my '00 Ford PS Intercooler. Now my whole front cooling assembly is from a '00 Ford.
Had to do minor surgery on the crossmember to remove the 460 motor mount pads.
Removed the gasser fuel vapor return line from frame.
Set valve lash on Cummins.
Attempted 2 ways to get the engine & transmission in place in the frame.:dang: Finally got too tired & called it a night. That was not encouraging!:argh:

Looks like you have made great progress on your truck. Keep up the good work. :c: