Hello: 2004 SMB converting gas to diesel

[Offroading_is_Fun]

Look as one of the bigger Ford Fan here, and not to be a turd in the punch bowl, I have to agree with Railvan. As many post on this forum about the 6.0 I am surprised to see someone actually putting in a 6.0 rather than pulling one out! I know it's too late so I will leave it alone and wish you the best of luck but I have to bow out with why not a Cummings? You needed a transmission and transfer case any way!

CA has some draconian laws about gas-to-diesel (Again, from what I remember. I doubt highly that a liberal 'go-green!' state would relax emissions laws to make it easier to pollute). Essentially the motor has to be the same model year or newer with all factory emissions systems in place. For Cummins, that means you could find a common rail and avoid some amount of the emissions pitfalls that you are stuck with for the 6.0, but rules out the 24v and 12v.

There might also be some consideration given that the 6.0 is "original Ford equipment" and all of the parts are already out there, where I'm sure the 5.9 certainly can be done, but is a more involved and perhaps costlier process.

To really have 'all of the opportunities' you need a 1997-1998 Econoline in CA. Lets you have your pick of the 12v, 24v, commonrail, or 7.3.

MY1997 in CA also happens to be smog-exempt if you run a diesel.

 

[Vanimal]

Yes very aware of the CARB laws, but hard to decipher. I say Cummings because the 6.7 would be a sweet implant. I had a 94 lined up but snoozed out on it. It would have received a Cummings. At present i am doing a 6.2 in an existing 6.2 Vandura, then A John Deere 3.9 into a 70 Scout if I ever get around to the Scout. I really do think you will be alright because the guys you are using have been around these. Be sure to keep it bulletproof ably simple!! Best of luck!

 

[DevilmtnDiesel]

Hello Group, I'm Jason with Devil Mountain Diesel. Thanks for the interest in this project. With out getting to long winded here are some current progress photos. Thanks and looking forward to this PROJECT! Jason

 

[Twoxentrix]

Jason (Devil Mountain Diesel), Think its great you chimed in here...IMO it reflects confidence!
This is the kind of endeavor that raises some eyebrows and attracts a curious audience (from several perspectives). Will be enlightening to follow this project...Looking forward to the end result.
Jeff94598 - I'm rooting for success & since your now on the stage with this, "break a leg" for luck - simply because it wont cost you anything, and its always welcome!

 

[Jeff94598]

Weekly progress and pizza meeting

Thanks Twoxentrix,

I'm sure I am going to need some positive support along the way as the process goes along.

There seems to be good progress being made, the motor mounts brackets that Jason shared were replaced and will enable the 6.0 motor that is being worked on currently to be installed when finished.

I have added a couple of photos of the motor progress and the newest piece of the project to arrive, the ATS transmission. I'll keep posting progress photos for those that are interested.

Jeff

 

[DevilmtnDiesel]

6.0 build update

Group- Some update engine build pictures.

 

[1der]

Sure is good looking!

 

[DevilmtnDiesel]

Thanks Ray! Here is a little more detail on what has been happening.

Group- The 6.0 Powerstroke for this project started life in a 2005 F250 4x4. The engine was running and had roughly 280,000 miles on the ticker.

First step was complete engine tear down. We sent the bare block and the new Mahle pistons to the local machine shop. The cylinder bores were matched to the new .020 pistons exact dimensions. This takes out any cylinder wall imperfections and lets our new piston rings start life on a fresh bore. The block deck was surfaced .005 to unsure it was perfectly flat. New camshaft bearings were installed as well. Crankshaft was checked for specs and polished to be reinstalled.
After machine work the bare block was thoroughly cleaned and prepped for reassembly.
Beginning the reassembly a new Ford spec camshaft was installed. Using the OTC cam/crank aligning tool and the upper half of the main bearings installed. We dropped in the crankshaft that was lubed with engine assembly lube on all bearing journals.
Which leads us to our first TIP to ensure a happy 6.0 life. The 6.0 Bedplate LEAKS! The solution started many years ago at the local Ford dealer. While the bedplate is upside down on the bench. After a thorough cleaning install the lower half of the bearings and the new Ford bedplate gaskets. Now use a small bead of Ford grey diesel silicone. Apply the bead parallel to the bedplate gasket working lengthwise. Make sure to place the bead on the inboard side of the gasket. We are trying to keep oil in, not road debris out. Now the complete bedplate gets reinstalled and torqued to factory spec. Now take a coffee break or better yet the next day come back and peal off any extra silicone that might be protruding into the inside of the engine.
Next the new ford connecting rods were fitted to pistons. Ford connecting rods come with new bushings in the little end and bearings for the big end. New rings will then be fitted to the piston and the piston assemblies were attached to the crankshaft. Remember to put assembly lube on all bearing surfaces. This now wraps up the short block build. We will talk cylinder heads next time.

 

[marret]

Awesome, looks great. Thanks for the info and posting Jason and Jeff.

 

[WhitH]

Great stuff! This is fascinating and worth following on many levels. Will this van be running truck tuning or will it get E series tuning...or something a little more custom?

 

[Vanimal]

Looks like it is going well. I did re-read your original post and you seem to have emphasized that you were looking for a diesel within budget. I am just curious and I will not ask but how is the budget going. I am sure there are many 6.0 guys wondering the actual present day cost to bulletproof a 6.0. The ATS is a good choice and will probably be my choice or Monster if I ever need one. It is good to see you picked a DIY front conversion!

 

[Vanimal]

It's been a long time since I looked into the specifics, but from what I remember, you are O.K. doing a gas-to-diesel swap provided that the MY of the engine is equal or "newer" to the MY of the vehicle it is being placed into, and still retains -all- factory-equipped emissions systems.

I have heard some smog/emissions refs are easier to get the paperwork done than with others (To make it "officially" powered by a diesel).

Puts the '97 vans into a great position- they can use just about anything (12v, 24v, commonrail, 7.3L, 6.0L) and be smog exempt in the state of CA. I can't remember if the motors had to be from the same manufacturer, or if you could mix and match dodge with Ford. Don't think I've ever seen or heard of a duramax swapped E-series.

Having a '97 with a 5.4L, I've long wondered about the prospect of a 24V or commonrail with a 'modern' transmission... but already having a Quigley conversion, I'm sure that shoehorning a diesel and big transmission in, in place of the 5.4L... Probably better off finding another 1997 van with ridiculous mileage/blown motor for cheap and starting there than ripping apart a perfectly good van.

Last I checked it had to be one year newer on Gas not sure on Diesel!

 

[Offroading_is_Fun]

Last I checked it had to be one year newer on Gas not sure on Diesel!

Not sure if that changes anything for 1997 vans- I think 1998 for Dodge was a bit like 2003 for Ford (12V/24V both 1998, 7.3/6.0 both 2003).

---

@DMD If I might pry for some info here... Why was a 6.0L elected over a commonrail 5.9? Compatibility would be my first guess, legal reasons being my second?

I presume this motor is going to end up being EGR-equipped?

Any 6.4 parts going on it(starter?)

Regarding earlier questions about the tunes being ran... I would be inclined to think a 6.0 sans-EGR would be able to run a hotter tune than one with.... Or is this motor destined to run standard E-series tunes in effort to maximize reliability?

 

[DevilmtnDiesel]

Bedplate reseal

Here are some photos to go along with the Bedplate reseal.

 

[DevilmtnDiesel]

@offroading is fun- The *6.0 was chosen mainly for what I will turn it into. A reliable, smooth running, powerful and "modern" diesel engine. *The fact that Ford used it as a factory installed engine never hurts when considering a swap or conversion candidate. *Being a California diesel repair shop the smog legal aspects are always part of this type of project. *
* This van and all vans worked on or built by DMD are EGR cooler equipped. *Thanks to Bullet Proof Diesel for building a cooler that has lasted the test of time and has earned its spot as the only EGR cooler we will install at DMD.
A 6.4 starter works fine, just not high on the build sheet yet. LOL
As far as tuning goes this van will live as a stock Econoline.

 

[Offroading_is_Fun]

@offroading is fun- The *6.0 was chosen mainly for what I will turn it into. A reliable, smooth running, powerful and "modern" diesel engine.
*The fact that Ford used it as a factory installed engine never hurts when considering a swap or conversion candidate.
*Being a California diesel repair shop the smog legal aspects are always part of this type of project.
* This van and all vans worked on or built by DMD are EGR cooler equipped. *Thanks to Bullet Proof Diesel for building a cooler that has lasted the test of time and has earned its spot as the only EGR cooler we will install at DMD.
A 6.4 starter works fine, just not high on the build sheet yet. LOL
As far as tuning goes this van will live as a stock Econoline.

Thanks for shedding some light on the project!

Look forward to seeing this all come together.

Erik

 

[Vanimal]

I honestly do not want to be a party pooper, really I don't.Never mind it is your post I just scratch my head???

 

[Jeff94598]

Hi Erik,

Sorry for delay in getting back, the donor truck had terrible interior, nothing of value. good luck in your search.
Jeff

 

[haywoodphotomaccom]

Following, just found out yesterday I will need a new V10 in my 2006. Looking at options. Are there options for a 2006?

 

[carringb]

Following, just found out yesterday I will need a new V10 in my 2006. Looking at options. Are there options for a 2006?

Why do you need a new V10? A Ford reman V10 is the best option. If you want to do a diesel conversion, putting a 6.0 is nuts, especially when the Cummins is a better fit and infinitely better motor.