Cost of a Cummins Swap

A Beginner’s Guide To What’s Really Involved In The Conversion Of Your Dreams

Whether it’s a Super Duty that’s being converted, a sled puller, a drag racer, an off-road vehicle, a rat-rod, or virtually any kind of daily driver, Cummins is king when it comes to engine swaps in the diesel world. But while a Cummins swap is the obvious and common choice for most builds, that doesn’t necessarily mean it will be cheap to pull off, or easy to perform. Measurements, locating a donor vehicle, and sourcing an engine are one thing, but actually dropping it into place and making it run and function can be a whole other story. Oftentimes, transmission selection, electronic integration, and the miscellaneous parts that are required to make the swap drivable consume the most time.

Then comes the custom components or solutions that can’t be bought but have to be made. If you’re not adept at fabricating, costs can skyrocket by enlisting the help of a professional. Being realistic with your own wrenching, welding, and electrical knowledge goes a long way in determining if you’re going the DIY route or having an independent shop handle the bulk of the work (if not all of it). In the following pages, we’ll run through a host of common engine and transmission combinations. Our aim is to highlight the unrealized, unexpected costs that can come up during the course of a Cummins swap—as well as give you an idea of what it will cost to have a professional perform the job for you.

Ford Super Duty Manual Shift — In the wide world of Cummins swaps, it doesn’t get any more economical than dropping a 12-valve into a Ford Super Duty that was originally equipped with a manual transmission, such as the ZF-6. With a throttle cable, transmission adapter plate and the appropriate flywheel and clutch combination, you’re essentially ready to roll after hooking up the starter. Depending on how you go about your parts sourcing, on a homemade project this type of swap can cost you a few thousand. For a clean, well-executed job performed at a reputable shop, you’ll likely be looking at a $7,000 to $9,000 bill.

Ford Super Duty 5R110W TorqShift — The 5R110W TorqShift employed in Super Duty’s from ’03-’10 is known for its durability behind either the 6.0L or 6.4L Power Stroke. However, if you plan to keep Ford’s five-speed automatic, at the very least a converter change will be required. Even in a mild horsepower application, a different stall speed (and potentially a much stronger) converter is mandatory to both harness and utilize the Cummins’ abundance of low-end torque.

Cummins with Ford 5R110W TorqShift — Going the 12-valve, 5R110 route can be pulled off for $12,000 to $15,000 at a shop that’s seasoned in Cummins swaps. Sprinkle in a little more power and the cost obviously goes up, but for a basic, 350hp (ish) 5.9L-powered ’03-’10 Super Duty you’ll get a Cummins repower that’s cleanly done and rock-solid reliable.

TCM-2800 Powertrain Control Solutions — Getting the 5R110 to play well with a 12-valve in front of it calls for a stand-alone transmission controller, not the Ford PCM. The most popular controller here is the TCM-2800 from Powertrain Control Solutions (PCS). The company’s TCM-2800 allows for fully programmable shift points, shift firmness, and control over torque converter lockup. You’re also given a base calibration to work with, along with sound technical support from the company itself. A TCM-2800 can easily be built into the aforementioned $12,000 to $15,000 swap cost if the conversion is being performed by a professional shop.

6.7L Cummins Diesel — Whether you’re performing the swap yourself or relying on someone else, you’ll spend considerably more coin on a common-rail Cummins swap. For Ford-Cummins conversions, even retaining the 5R110 transmission will still call for a $20,000 to $25,000 budget if you’re enlisting a veteran swap shop’s help—and that’s a basic setup, though done cleanly and correctly. As with a 12-valve swap, added go-fast parts will add to the overall cost.

4BT Cummins engine — If space under the hood is a major concern, it’s hard to beat the packaging size of a 4BT. One of the biggest advantages of the 6BT’s little brother is that its shorter, 30-inch overall length leaves plenty of room for an engine fan. The 4BT Cummins remains a popular swap candidate for this very reason—along with the fact that virtually any transmission can be bolted up to it with the right adapter plate and appropriate flex plate or flywheel/clutch in the mix.

Electric fan, shroud, radiator package — Given the choice between a mechanical clutch fan and an electric one, the former is the preferred means of engine cooling in any swap project that’s intended to be a tow vehicle. However, in applications where space doesn’t permit the use of a mechanical clutch fan arrangement, electric fans with a proper shroud and radiator package can be made to work effectively.

This simple Cummins fan hub adapter (made by GOS Performance and available through Strictly Diesel) is the solution to all of the engine fan problems encountered in common-rail Fummins projects. Instead of relying on the electronic engine fan employed on Cummins engines, which can struggle to cool adequately, the adapter allows for the use of a Ford mechanical clutch fan. Specifically, combining the mechanical fan clutch from the ’94.5-’97 7.3L Power Stroke with the 23.25-inch diameter fan off of the 6.0L Power Stroke tends to work best.

Due to its lack of emissions controls (and thanks to its immense power potential), the 5.9L common-rail remains a popular engine swap candidate, across the nation. Right beside it in popularity? The 48RE four-speed. Even in 6.7L applications, the 48RE is often chosen over a built 68RFE or an Allison. This is because the 48RE can be made extremely durable with the right parts, parts for it are readily available, and it’s not stupid expensive to prep one for handling additional power.

Considered the holy grail by some, the common-rail Cummins/Allison transmission combo is the ultimate budget blower. First and foremost, the Cummins and Allison can’t talk to each other without help, which also means you get no torque management—and in Ford trucks neither the Cummins nor the Allison will communicate with the Ford electronics. Granted, this can be solved, but there is a reason this is the most expensive combination to run. If you’re dead-set on a common-rail Cummins/Allison powertrain and are having a shop handle your swap, be prepared to spend at least $30,000. The six-speed Allison 1000 controller kit from DeStroked is shown here, which includes the TCM, XFC, and wiring harness you’ll need to integrate an Allison behind any Cummins (or even any engine) you choose.

Then there is the added cost of building the Allison… Unless you’re sticking with a 350hp Cummins, the A1000 won’t tolerate the kind of low-end torque even a mildly powerful 5.9L or 6.7L Cummins can dish out. And, like any other automatic transmission in the diesel industry, the Allison isn’t cheap to reinforce.

Custom-made parts can bring a conversion project to a standstill if you can’t fabricate or wire on your own, but depending on the vehicle you’ve chosen for your swap it can be 100-percent necessary. Especially when you’re out of space under the hood, things like a custom-sized radiator, intercooler (or even water to air unit), expansion tank, or even a compact air cleaner setup may be unavoidable.

Depending on how you compile all the parts required to pull off your particular Cummins swap, it may seem like there are a thousand odds and ends to hunt down throughout the process. For instance, if your 12-valve came out of an old medium-duty application, you may have to source a different water inlet manifold and thermostat housing, or have to change the alternator’s location.

’03-’04 Dodge Cummins throttle bell crank — As another example of how little things can add up in a Cummins swap, many find that an ’03-’04 throttle bell crank is required to swap their later 5.9L common-rail into place. The only problem is that they aren’t cheap, starting at roughly $250 for a used one ($600 or more new)—and then you need the throttle cable as well…

Diesel Conversion Specialists pedal bracket kit with adjustable pedal — Even on 12-valve into Ford swaps, things aren’t always cut and dry. Short of buying an install kit, you’ll have to find a way to make the Ford pedal accept the Cummins’ throttle cable. Diesel Conversion Specialists offers a pedal bracket kit with an adjustable pedal to solve this very thing on ’05-’10 Fords.

Whether you’re up to the task of wiring your Cummins swap or not, it has to be done. Modifying (or blending, as it’s often referred) the engine harness is a good idea in every scenario, 12-valve, 24-valve, or common-rail, to make the engine’s integration as complete as possible. Even sending off the wiring harness for a mechanical, 12-valve Cummins that’s been dropped into a Ford is worthwhile as it can ensure the gauges in the cluster work flawlessly. Both DeStroked Colorado and Diesel Conversion Specialists offer these types of blending services, and they are beyond worth the cost.

Adding better electronics to early common-rail engines can be a big help. Swap enthusiasts using ’03 and ’04 5.9L’s for their conversions can utilize ’06-’07 model year electronic components such as the ECM, TIPM, engine harness, and even injectors to allow for true drive-by-wire capability and better engine tuning and performance options. Upgrading to later style electronics is also ideal when an early 5.9L common-rail is purchased without any electronics.

2500 Dodge Ram Cummins truck — Some of the best advice you can get when it comes to Cummins swaps is to find a complete donor truck. Anyone who’s serious about performing a Cummins conversion gets things started with a donor truck, be it a wrecked Ram with parts to pick from, a retired work truck, or a barn find. Not only can you come up with your own engine this way, but you may have a transmission, axles, transfer case, and wiring at your disposal, too.

shift on the fly switch — The bottom line on any Cummins swap is that you have to be resourceful. Trust us, even though there are great conversion kits available in the aftermarket, you’re still going to have to hunt down parts. And if you decide on an electronically controlled engine, the work continues long after you’re done wrenching. For most do-it-yourselfers, getting a common-rail Cummins fine-tuned to the point where it runs, works, and drives flawlessly is the hardest part.

first gen 12 valve Dodge Cummins engine — For utmost reliability, it’s virtually impossible to beat keeping things simple. By that we mean stick with a 12-valve swap and a manual transmission, especially if you’re a newcomer to the Cummins conversion game. Trust us, the common-rail Cummins/Allison transmission combo in a Ford Super Duty does (and always will) be appealing, but you may fight inevitable and intermittent issues (big and small) for some time. However, if you do travel that path, make sure you pick the brains of experts that know exactly how to execute that type of swap, such as DeStroked Colorado or Diesel Conversions Specialists.

12 valve cummins diesel, OBS Chevy truck — Before you commit to anything (be it with yourself or a shop), do your own research. See what’s been done before and don’t try to reinvent the wheel. If you are going to have a shop handle the swap, run your desired truck, engine, transmission, and horsepower plans by them before you start rounding up parts. Seek their advice on what would best suit your needs. Last but not least, make sure they’ve performed Cummins swaps in the past. The last thing you want is a shop that’s learning as they go or outsourcing much of the work.

custom 12 valve Cummins p-pumped engine — Once you’ve committed to the vehicle application, engine, and transmission of your choice, start measuring. Pay special attention to motor mount and accessory drive locations. For example: on OBS Ford trucks the common-rail Cummins doesn’t fit well due to the power steering pump being pulley driven, which protrudes down and causes interference with the power steering box on the frame. In contrast, the power steering pumps on the 12-valve and 24-valve engines are gear driven (courtesy of the front gear train) and are much more clearance-friendly.

Cummins engine block — No matter which Cummins you choose, start fresh. Installing a take-out engine and assuming it will run forever can lead to downtime and more costs sooner rather than later. A hurt cylinder, warped head, bad injector, or broken piston cooling nozzle might not be information the engine seller will offer up when you buy the engine, so it behooves you to begin anew. Even a reseal will give you an internal glimpse of the engine’s overall health.

tear down of a transmission — The same goes for the transmission you pick to live behind the Cummins. Regardless of its apparent condition, don’t take a chance. Have it torn down and looked over. If you’re adding power to the Cummins this is the time to upgrade the transmission anyway. By rebuilding or reinforcing the transmission now you’re money ahead of a take-out unit that could potentially self-destruct and take everything out with it.

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FREQUENTLY ASKED QUESTIONS

What are the benefits of performing a Cummins engine swap in a vehicle?

Swapping a Cummins engine into your vehicle offers a world of benefits that appeal to a variety of automotive enthusiasts, from off-road adventurers to performance aficionados. Here’s why a Cummins conversion might be right for you:

1. Enhanced Fuel Efficiency

Cummins engines are renowned for their impressive fuel economy. Whether you’re hitting the open road or tackling tough terrains, you’ll likely notice fewer stops at the pump, a crucial factor for those long-haul trips.

2. Exceptional Torque and Power

One of the standout features of Cummins engines is their unparalleled low-end torque. This translates into superior towing capacity and performance, making them an ideal choice for tasks like sled pulling or drag racing. You can even enhance the engine’s horsepower significantly without compromising its longevity.

3. Longevity and Durability

These engines are designed to last. Known for their million-mile durability, a Cummins engine can offer peace of mind as well as a return on investment. This reliability makes them desirable for rat-rod builders and those who demand longevity in their vehicles.

4. Versatility Across Models

From the classic 4BT and 6BT to the more modern common-rail engines, Cummins provides a range of options that cater to different needs and preferences. Each model has its own strengths but shares the core benefits of robustness and efficiency.

5. Boosted Resale Value

Vehicles with Cummins swaps can see increased resale value due to the reputation for quality and performance associated with these engines. For many enthusiasts, this prospect alone is worth considering the conversion.

In summary, a Cummins engine swap offers a combination of efficiency, power, and durability, making it an enticing upgrade for those wanting to push their vehicles to new heights.

Is there a general parts list that applies regardless of the specific Cummins engine being used?

Yes, there is a general list that includes items like the adapter plate, motor mounts, and a conversion harness or module, which are commonly required for various Cummins engine installations.

What is the potential cost of an aftermarket conversion kit?

An all-inclusive aftermarket conversion kit can range from $3,000 to $6,000, depending on your specific needs and the components included.

What are the essential components for a Cummins engine conversion?

For a successful Cummins engine conversion, you’ll typically need an adapter plate, a flex plate or clutch for manual transmissions, motor mounts specific to your engine, and a conversion engine harness or an aftermarket module to ensure communication between the engine and transmission.

What additional requirements are there if retaining the factory automatic transmission?

If you retain the factory automatic transmission, you’ll need a stand-alone transmission controller and a torque converter that is compatible with the Cummins engine.

How does choosing a manual transmission affect the complexity of the swap?

Opting for a manual transmission simplifies the swap process by reducing the need for complex electronic controls, making it a more straightforward installation.

What components are necessary for a 6BT Cummins swap?

Essential components for the swap include a throttle cable, a shut-off solenoid if desired, an adapter plate, and a clutch when using a manual transmission setup.

How do miscellaneous parts contribute to the overall cost of a Cummins swap?

Measurements, locating a donor vehicle, and sourcing an engine are one thing, but actually dropping it into place and making it run and function can be a whole other story. Oftentimes, transmission selection, electronic integration, and the miscellaneous parts that are required to make the swap drivable consume the most time.

For instance, the cost of tracking down various components can quickly add up. A 12-valve 5.9L Cummins engine from a different vehicle might require a unique water inlet manifold and thermostat housing, which aren’t always easy to find. Moreover, if you’re using a 5.9L common-rail Cummins from a Ram 2500 or 3500, you might need to source an earlier model year bell crank, a part that’s both elusive and pricey.

Then comes the custom components or solutions that can’t be bought but have to be made. You’ll often find yourself piecing together an air intake, modifying the engine harness to ensure compatibility with the gauge cluster, and even relocating the passenger battery to the driver side of the engine bay in certain trucks. Additionally, replacing a leak-prone vacuum/power steering pump with a reliable gear-driven unit is common practice.

If you’re not adept at fabricating, costs can skyrocket by enlisting the help of a professional. These unforeseen tasks and the sourcing of specific parts underline how miscellaneous costs can escalate, making the swap more challenging than it initially appears.

What are the challenges of finding specific parts for a Cummins swap, and how do they impact cost?

Locating certain parts, such as the bell crank for specific model years, can be challenging and expensive, adding to the overall project cost.

What are some common modifications or upgrades required during a Cummins swap?

Modifications often include integrating the engine harness with the vehicle’s gauge cluster, relocating the battery, and upgrading the power steering pump to a gear-driven unit in some applications.

How do engine models and years affect parts compatibility and sourcing for a swap?

Different engine models and production years, like the 12-valve Cummins from an F600 versus a Dodge Ram, can require distinct components, which affects compatibility and sourcing needs.

What are some specific parts that need to be sourced for a Cummins swap?

Parts such as the water inlet manifold and thermostat housing are essential, particularly since they can vary depending on the engine’s original vehicle. Additionally, a bell crank may be necessary for certain model years.

What steps should be taken to ensure the Cummins engine is in good condition before a swap?

No matter which Cummins you choose, start fresh. Installing a take-out engine and assuming it will run forever can lead to downtime and more costs sooner rather than later. A hurt cylinder, warped head, bad injector, or broken piston cooling nozzle might not be information the engine seller will offer up when you buy the engine, so it behooves you to begin anew. Even a reseal will give you an internal glimpse of the engine’s overall health.

Taking proactive steps is crucial. Here’s a step-by-step approach to ensure your Cummins is in top condition before a swap:

Perform a Full Reseal: This allows you to inspect the internal components and address any hidden issues. It’s a small investment that can prevent major headaches.
Inspect Key Components: Pay close attention to the piston cooling nozzles, cylinder head, injectors, and cylinders. These parts are often prone to issues that can significantly affect performance.
Start Fresh: Consider this an opportunity to renew the engine’s life and reliability. Cummins engines are known for their durability, but ensuring each component is in excellent condition will maintain this reputation.
Financial Prudence: Investing time and resources now can save you thousands in potential repairs down the line. Avoid the costly mistake of having to remove the engine again due to preventable issues.

The same goes for the transmission you pick to live behind the Cummins. Regardless of its apparent condition, don’t take a chance. Have it torn down and looked over. If you’re adding power to the Cummins, this is the time to upgrade the transmission anyway. By rebuilding or reinforcing the transmission now, you’re money ahead of a take-out unit that could potentially self-destruct and take everything out with it.

By following these recommendations, you’re not just ensuring a smooth swap but also safeguarding your investment for the future.

How can a preliminary engine inspection save money in the long run?

By addressing all potential issues and performing necessary repairs at the outset, you can avoid the expense of future breakdowns and repairs, ultimately saving thousands.

What motivates people to choose a Cummins engine?

Many opt for Cummins engines because of their strong reputation for reliability and performance, making them a popular choice for swaps.

What are the potential consequences of not thoroughly inspecting the engine?

Failing to conduct a comprehensive inspection could lead to costly repairs down the line. Overlooking initial issues might result in significant financial burdens if major components fail unexpectedly.

What specific components or issues should be checked in the engine?

Key areas to inspect include the piston cooling nozzle, cylinder head, injectors, and cylinders. These components can develop problems that may not be immediately visible during a purchase.

Why is it important to start fresh with a Cummins engine swap?

Beginning with a clean slate ensures that any hidden issues are addressed upfront. This proactive approach prevents the hassle of having to remove and reinstall the engine due to undisclosed problems.

What is the current market situation for donor trucks?

Despite high demand in the used car market, affordable options for wrecked trucks are still available, allowing for budget-friendly opportunities to acquire a donor vehicle.

What components can you expect to obtain from a donor truck?

A donor truck typically provides essential components such as the engine, transmission, wiring, and possibly some running gear, which are crucial for the swap.

How can you offset the costs of a Cummins swap project?

By selling off leftover parts from the donor truck, you can recover some of the expenses incurred during the project, making the swap more financially feasible.

What are the potential costs of sourcing a donor truck?

Depending on the model year, wrecked Dodge trucks can be acquired for anywhere between $3,000 and $15,000, providing a range of budget options for sourcing a donor vehicle.

What specific challenges are associated with the high-tech, high-pressure injection system of common-rail engines compared to older mechanical systems?

The high-tech, high-pressure injection systems in common-rail engines are complex and costly, especially when compared to the simpler mechanical systems like the 6BT engines.

What is the total estimated cost for a common-rail Cummins swap into a specific vehicle model, such as a late-model Ford Super Duty?

For a swap into a late-model Ford Super Duty, the estimated total cost is between $20,000 and $25,000.

How do the costs of a common-rail Cummins swap vary with different transmission choices?

The overall expense of a common-rail Cummins swap is influenced by the transmission selected, as each option may entail different costs and complexities.

What is the cost range for acquiring a donor engine for a common-rail Cummins swap?

The cost for a donor engine in a common-rail Cummins swap can range from $2,000 to $8,000.

How does time factor into the swap process?

Time is a significant factor, as the process requires substantial effort and planning. Whether doing it yourself or hiring professionals, the engine swap is not a quick undertaking and demands careful scheduling and patience.

Where can one find the supporting parts needed for the swap?

Supporting parts can be sourced from local salvage yards, as well as online platforms like Marketplace and eBay. These venues offer a range of components necessary to complete the engine swap.

How important is resourcefulness in the process?

Resourcefulness is crucial, especially for those on a tight budget. It involves exploring various avenues to find engines and parts, which can significantly impact the overall cost and success of the swap.

Why is the cost a factor in a Cummins engine swap?

The expense arises because Cummins engines are not cheap, and the process of installing one is complex. If you opt for professional installation, the costs can exceed initial estimates, making budgeting a critical part of the project.

What are the challenges of performing a Cummins swap on your own?

Undertaking a Cummins conversion project on your own isn’t for the faint of heart. It’s always more time-consuming than it appears to be on the surface, and even a well-trained mechanic could have 100 man-hours in a ‘simple’ 12-valve swap. For beginners and those unfamiliar with vehicle electronics, sticking with a 12-valve 6BT or 4BT Cummins engine and a manual transmission is advisable. This not only helps keep costs down but also increases the likelihood of ending up with a reliable vehicle.

Depending on how you compile all the parts required to pull off your particular Cummins swap, it may seem like there are a thousand odds and ends to hunt down throughout the process. For instance, if your 12-valve came out of an old medium-duty application, you may have to source a different water inlet manifold and thermostat housing, or have to change the alternator’s location.

As another example of how little things can add up in a Cummins swap, many find that an ’03-’04 throttle bell crank is required to swap their later 5.9L common-rail into place. The only problem is that they aren’t cheap, starting at roughly $250 for a used one ($600 or more new)—and then you need the throttle cable as well…

Even on 12-valve into Ford swaps, things aren’t always cut and dry. Short of buying an install kit, you’ll have to find a way to make the Ford pedal accept the Cummins’ throttle cable. Diesel Conversion Specialists offers a pedal bracket kit with an adjustable pedal to solve this very thing on ’05-’10 Fords.

Whether you’re up to the task of wiring your Cummins swap or not, it has to be done. Modifying (or blending, as it’s often referred) the engine harness is a good idea in every scenario, 12-valve, 24-valve, or common-rail, to make the engine’s integration as complete as possible. Even sending off the wiring harness for a mechanical, 12-valve Cummins that’s been dropped into a Ford is worthwhile as it can ensure the gauges in the cluster work flawlessly. Both DeStroked Colorado and Diesel Conversion Specialists offer these types of blending services, and they are beyond worth the cost.

In summary, while the allure of a Cummins swap is strong, approaching it with a clear understanding of the challenges—time, cost, skill, and the need for custom solutions—can make the difference between a successful project and an unfinished dream.

What are the key considerations for a novice?

Novices should focus on simpler engine and transmission combinations to keep the project manageable. It is crucial to understand one’s own skill limitations and to seek professional assistance if necessary, especially when dealing with complex vehicle electronics.

What is the likelihood of achieving a reliable outcome?

Choosing the recommended engine types and transmission setup increases the likelihood of ending up with a reliable vehicle. This approach is the most probable way to achieve a dependable outcome, as it aligns with proven, straightforward conversion methods.

How can costs be managed?

To manage costs effectively, opting for a 12-valve 6BT or 4BT engine and a manual transmission is recommended. This approach helps minimize expenses by simplifying the swap process and reducing the need for additional, costly modifications.

How much time is involved in a swap?

The time required for a Cummins swap can be substantial. Even for a seasoned mechanic, a straightforward 12-valve swap can take around 100 man-hours. This emphasizes the need for careful planning and realistic scheduling when undertaking such a project.

Who should attempt a Cummins swap?

A Cummins swap is best suited for individuals with some experience in vehicle mechanics, particularly those familiar with engine swaps. Beginners or those not well-versed in vehicle electronics should consider sticking with simpler engine options like the 12-valve 6BT or 4BT, paired with a manual transmission, to increase the chances of a successful project.

What are some cost-effective ways to source a Cummins engine for a swap?

Some of the best advice you can get when it comes to Cummins swaps is to find a complete donor truck. Anyone who’s serious about performing a Cummins conversion gets things started with a donor truck, be it a wrecked Ramwith parts to pick from, a retired work truck, or a barn find. Not only can you come up with your own engine this way, but you may have a transmission, axles, transfer case, and wiring at your disposal, too.

Cost-Effective Options for Sourcing

Wrecked Trucks: Despite the current heat of the used car market, you can still find wrecked trucks at reasonable prices. Depending on the model year, a wrecked Dodge truck might cost between $3,000 and $15,000. This investment often includes the engine, transmission, wiring, and possibly some running gear essential for your swap project.
Parting Out the Donor: Once your build is complete, consider parting out the remaining components of the donor truck. This can help offset some of the initial costs, making the investment even more economical.
Bargain Finds: Look for popular Cummins-swap recipient trucks, such as certain Ford models from 2003 to 2010, which can sometimes be found fully-loaded but with blown engines for as low as $5,000 to $8,000.

By exploring these strategies, you can source a Cummins engine and other necessary parts without breaking the bank.

What advice is given for having an independent shop perform a Cummins swap?

Before you commit to anything (be it with yourself or a shop), do your own research. See what’s been done before and don’t try to reinvent the wheel.

Planning Your Cummins Swap

Determine exactly which setup you want to pursue. Whether you’re considering a 12-valve 5.9L Cummins paired with a 47RH transmission, a 4BT/NV4500 combo, or a common-rail 6.7L with a Ford TorqShift, it’s essential to have a clear plan.

Consulting with the Shop

If you are going to have a shop handle the swap, run your desired truck, engine, transmission, and horsepower plans by them before you start rounding up parts. Seek their advice on what would best suit your needs. It’s crucial to pick their brain about your preferred engine and transmission combination and get their input before making any purchases—be it parts, engines, transmissions, or even a donor truck.

Evaluating Shop Experience

Last but not least, make sure they’ve performed Cummins swaps in the past. Don’t hesitate to ask how many swaps they’ve completed and request to see examples of their work. The last thing you want is a shop that’s learning as they go or outsourcing much of the work. This can lead to unnecessary costs and mistakes at your expense, so confirming their expertise is vital.

By taking these steps, you can ensure a smoother, more successful Cummins swap, minimizing potential headaches and maximizing satisfaction with your project.

What should you do with your truck, engine, and transmission plans before starting a swap?

Discuss your plans with the shop, including the specific truck, engine, transmission, and desired horsepower. This helps tailor the swap to your needs and ensures that all components are compatible and meet your expectations.

Why is it important to verify a shop’s Cummins swap experience?

Ensuring the shop has substantial experience prevents them from learning at your expense and avoids the potential for outsourced work, which could affect quality and timelines.

How can you verify a shop’s experience with Cummins swaps?

Ask the shop about the number of Cummins swaps they’ve completed. Request to see examples of their past work to get a sense of their expertise and quality.

When should you consult with a shop regarding your Cummins swap?

It’s best to consult with the shop before making any purchases, whether it’s parts, an engine, a transmission, or even a donor truck. This ensures that your selections align with the shop’s capabilities and recommendations.

What are some potential engine and transmission combinations for a Cummins swap?

You might consider options like the 12-valve 5.9L Cummins paired with a 47RH transmission, or perhaps a 4BT engine with an NV4500 transmission. For those interested in newer technology, a common-rail 6.7L engine matched with a Ford TorqShift setup could be appealing.

What advantages does a 4BT Cummins engine offer over a 6BT in a swap?

One of the biggest advantages of the 6BT’s little brother is that its shorter, 30-inch overall length leaves plenty of room for an engine fan. The 4BT Cummins remains a popular swap candidate for this very reason—along with the fact that virtually any transmission can be bolted up to it with the right adapter plate and appropriate flex plate or flywheel/clutch in the mix.

But there’s more to the 4BT than just its compact size and versatility. Its reduced length means it can fit snugly into vehicles with smaller engine bays, making it an ideal choice for those tight swap spaces. This extra room ensures you can easily accommodate essential components like the radiator, fan, and fan shroud, which are crucial for maintaining optimal engine temperature.

Moreover, the 4BT is approximately 300 pounds lighter than the 6BT. This weight reduction is particularly beneficial for vehicles with moderately-sized front axles and light-duty suspension systems, such as Jeep Wranglers, Ford Rangers, and Toyotas. This means less wear and tear on your vehicle’s suspension, extending the life of your swap candidate.

In essence, the 4BT Cummins not only offers flexibility and space efficiency but also ensures that your vehicle’s essential components are preserved, making it a smart choice for a wide range of automotive enthusiasts.

How expensive is it to purchase a Cummins engine for a vehicle swap?

Purchasing a Cummins engine to swap into another vehicle is not a budget-friendly endeavor. The cost of the engine itself has risen over the years, and the process is far from a straightforward installation.

For those tackling a DIY project, be prepared to invest substantial time and effort. This isn’t a quick weekend job by any means. If you’re hiring professionals to handle the swap, expect the labor costs to exceed your initial estimates. Shop fees can stack up quickly, especially if complications arise during the installation.

If your budget is tight, consider some creative alternatives. Scouting for a Cummins engine in a wrecked Dodge Ram or an older medium-duty truck can be a more affordable route. Another option is to explore used generator sets to find the engine type you need.

Don’t forget the additional expenses for all necessary supporting parts. Regularly check online marketplaces, local salvage yards, or platforms like eBay for these components. These options might help you save money compared to purchasing everything brand new.

In summary, while the allure of a Cummins swap is strong, it’s essential to be financially prepared and resourceful in your approach.

Why is it important to ensure the Cummins engine is in good condition before beginning a swap?

Why Start Fresh?

Avoid Future Hassles: Without a thorough inspection, you might find yourself pulling the engine back out to address hidden issues. This can be a major inconvenience and add to your project costs.
Identify Hidden Problems: Issues like a failed piston cooling nozzle or a warped cylinder head can easily be masked. Starting with a clean slate ensures you’re not inheriting someone else’s problems.
Financial Prudence: Spending on a full once-over or necessary repairs now can save you thousands in the long run. It’s an investment in the engine’s longevity and reliability.
Maintain Reputation: You’ve likely chosen a Cummins engine for its distinguished reliability. Ensuring it is in top condition upholds this reputation and your confidence in its performance.

A fresh start sets the stage for a successful swap, minimizing risks and maximizing benefits.

Why is it important to maintain the engine’s reputation for reliability?

Ensuring the engine is in optimal condition helps preserve the Cummins’ renowned reliability, which is likely a key reason for selecting this engine for your project.

How can addressing these issues now benefit you financially?

By conducting a thorough inspection and necessary repairs upfront, you can potentially avoid costly repairs down the line, saving a significant amount of money.

What specific issues might be hidden within a used engine?

Issues such as malfunctioning piston cooling nozzles, warped cylinder heads, faulty injectors, or damaged cylinders might be concealed within a used engine and not disclosed by the seller.

What are the potential consequences of not ensuring the engine is in good condition?

If you skip checking the engine’s condition, you might face the hassle of removing it again due to unforeseen issues. This can lead to repeated labor and increased downtime.

Why is a Cummins engine paired with an Allison transmission considered desirable?

Considered the holy grail by some, the common-rail Cummins/Allison transmission combo is the ultimate budget blower. This pairing is revered in the diesel truck community for a reason. It combines the robust power delivery of a Cummins engine with the smooth and reliable shifting of an Allison transmission, making it a top choice for enthusiasts seeking performance and durability.

Many folks in the diesel realm view this combo as the “end-all, be-all.” The Cummins engine’s legendary torque and longevity, coupled with the Allison transmission’s ability to handle high power outputs, create a driving experience that’s hard to match. When installed in a Ford Super Duty, the combination is often considered the best of all worlds, providing unmatched power and reliability.

First and foremost, the Cummins and Allison can’t talk to each other without help, which also means you get no torque management—and in Ford trucks, neither the Cummins nor the Allison will communicate with the Fordelectronics. Granted, this can be solved, but there is a reason this is the most expensive combination to run. If you’re dead-set on a common-rail Cummins/Allison powertrain and are having a shop handle your swap, be prepared to spend at least $30,000.

The six-speed Allison 1000 controller kit from DeStroked is shown here, which includes the TCM, XFC, and wiring harness you’ll need to integrate an Allison behind any Cummins (or even any engine) you choose. Despite the challenges and costs, the allure of this powerhouse combination continues to captivate truck enthusiasts, making it a coveted modification for those seeking the ultimate in diesel performance.

What makes this combination the “best of all worlds”?

When integrated into a Ford Super Duty, this pairing is believed to offer the optimal balance of performance, durability, and versatility. This setup harnesses the strengths of each component, providing a superior driving experience compared to other configurations.

Why is the Cummins engine paired with an Allison transmission considered the “end-all, be-all”?

This combination is revered in the diesel truck community for its exceptional performance and reliability. It is often seen as the ultimate setup that delivers both power and efficiency, making it a top choice for enthusiasts.