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2008-2010 Ford 5.4L or 6.8L

2008-2010 Ford 5.4L or 6.8L

2008-2010 Ford 5.4L or 6.8L

When it comes to sheer power and performance, the 6.8 Cummins shines in every category. Whether for heavy-duty hauling or off-road adventures, the exceptional capabilities of this engine leave many in awe. Not to mention the 6.7 Cummins 8 cylinder, recognized in the motor world for its reliable and robust performance. Our extensive range of parts and accessories facilitate the functioning of these engines, right from the 2008-2010 Ford 5.4L, ascending towards the superior 6.8L models. Customizing your ride for optimal performance just became a whole lot easier.

Many times customers ask about converting 2008-2010 Ford® 5.4 and 6.8 trucks to a diesel due to the fact that they can be purchased reasonably, or they already have one and would like diesel power. There is not too much difficulty with this conversion, as these trucks have the same frame and transmission mounting as the diesel versions. You should plan to drop the fuel tank and remove the electric fuel pump. This is explained further in the installation manual. Keep in mind that a new diesel exhaust system will also be required and a diesel radiator is also a good idea if you plan to do some considerable hauling. The 2008-2010 Ford radiator and intercooler swap requires more parts than the earlier 2003-2007 models- and if the parts are bought brand new they are fairly expensive. TRANSMISSIONS 5.4 AND 6.8 AUTOMATIC TRANSMISSION SECTION The 5R110’s are a 5-speed automatic that comes behind the 2008-2010 5.4 and 6.8 Fords. If you plan on doing some pulling, we would highly recommend getting a diesel torque converter. See our Cummins to Ford 5R110 Torqshift article for more information. Ford 6-Speed – The 6-speed manual would be a very rare option in one of these trucks. WE currently do not make a 5.4 or 6.8 6-speed adapter plate due to the small clutch that would have to be used with one. We make adapter plates for the 7.3 and 6.0L diesel 6-speed. These are very good transmissions for the conversion, and worth the time swapping in if you want a manual trans INFORMATION ON PARTS IN OUR KITS ADAPTER PLATE Our adapter plate kit uses the 6.0L Ford Power Stroke starter. It is actually the same adapter that was designed for the 6.0L 5R110 automatic transmission but it also works for the 4R100, and allows you to upgrade to the 5R110 in the future if you'd like. Two holes in the top of the adapter are not used (the 4R100 does not have these holes and two in the bottom are not used either) or if you want to use them drilling out the threads in the bottom holes in the transmission is required. The adapter plate is sold with the required custom flexplate. Our adapter plate replaces the adapter already on the back of the Cummins engine, making a factory quality connection for the transmission. They are precision machined from aircraft grade (6061) aluminum. ENGINE MOUNTS Our motor mounts are pre-drilled to accommodate for the stock engine fan (recommended). Because the Cummins engines are longer this will move your transmission back 2” to 3” causing you to move your transmission cross member back. The engine mounts are an excellent design with a bolt going all the way through the isolator, instead of relying on rubber and weak interlocking tabs to secure them to the frame cross member. You may be able to utilize our custom carrier bearing mount, which may make it possible to use your drive shafts as they are with an engine driven fan. This mount replaces your stock carrier bearing mount and moves the carrier bearing back just enough to give you room for the engine driven fan by collapsing the slip joint in your rear drive shaft. It is necessary for you to make sure you will still have enough slip in the joint when your rear suspension is compressed. Usually the rear drive shaft is fairly level in trucks that do not have a lift kit, so the drive shaft does not need to collapse very much during suspension travel. In most cases the front drive shaft on four-wheel drives will stretch enough to reach the front differential. It is necessary to move the transmission cross member back or lengthen the slots in the mount to slide the transmission back enough to give room for the engine driven fan. Automatic trucks already have holes in the frame to move the cross member back to accommodate the Dodge Cummins engine driven fan. GAUGE SENDING UNIT ADAPTERS (BUSHING KIT) Bushing kits include our custom built adapters to put your Ford gauge sending units into the Cummins engine so that your stock gauges still work with the Cummins engine. ALTERNATOR MOUNT CPP currently offers an alternator mount that allows you to use the 6.0/6.4L alternator if you would like. The advantages of using this alternator is that your indicator light will still work as it should if your charging system should fail, because they are internally similar to the 5.4 or 6.8 alternator. If you would rather use the Dodge Cummins alternator, we can provide you with an external voltage regulator. Common Rail applications do not need the external regulator. EXHAUST MANIFOLDS CPP sell exhaust manifolds that work much better in the conversion for the 12-Valve and 1998½ - 2002 24-Valve engines. These manifolds place the turbo in a better place for A/C box clearance than the stock variety, and also make exhaust and turbo oil drain connections easier as well. For the 24-Valve engines, other exhaust pieces are necessary when using our exhaust manifolds to provide an adjustable elbow connection for the downpipe. Both of these manifolds require you to re-orient your turbo housings to allow your oil drain to be pointed down correctly. This usually requires you to heat the exhaust housing on the turbo to remove the bolts and the housing so the housing can be re-oriented. Either fixing the waste gate shut or using a different waste gate actuator we can provide is also necessary because once the turbo is re-oriented the actuator will hit the engine block. Fixing the waste gate shut does not usually have any adverse effects on the engine, but we do recommend using a boost gauge to monitor and limit boost pressures to less than 40 psi. CPP also offers manifold gaskets and new exhaust manifold to turbo studs if you would rather not try to get the studs out of your stock manifold. Also helpful is a flexible turbo drain tube that connects to the stock hose and elbow that is left in your engine block when you remove the stock drain tube connected to the turbo. If you would rather, it is possible to heat this tube up to bend and twist it to allow reconnecting it after you re-orient your turbo housings. TACH KIT The tach kit consists of the Base, Mount, Sensor, and tach ring. These parts are necessary to make your factory tachometer work. Providing this signal to your Ford PCM computer also is necessary for the air conditioning, factory transmission control, and transmission temperature gauge to work as well. The universal sensor and mount we offer makes is the easiest way to supply the tach signal, since we currently do not make a mount for the stock 5.4 or 6.8 crank sensor. If you have the time, you can make a bracket for your stock crank sensor and save some money if you wish, although they are quite awkward to mount. Most 12-Valve engines 1994 and newer already have the tach sensor base, which is bolted to the front cover at about 11:00 to the balancer. You will have to drill and tap a hole in it for our sensor mount to bolt to it. All 2008-2010 5.4 or 6.8 trucks require the tach ring that bolts onto the front of the Cummins crankshaft balancer, for the sensor to send the correct signal pulse to the Ford PCM that makes the tachometer work. It is not necessary to buy a diesel instrument cluster for your truck. TRANSMISSION CONTROLLER See the Cummins to Ford 5R110 Torqshift article for more information. AIR FILTER KIT Our air filter kit includes a Brute Force air filter, pipe and hose to connect to your turbocharger. We offer two styles of air filter kits. The kit normally used in the 5.4 or 6.8 liter truck is the Part #1941. It requires relocating the passenger side battery to the driver’s side. Some customers use a larger single battery mounted in the original air filter box. The original battery tray also works well for the new air filter. Others have used two batteries in the same location, but this takes some fabricating skill to make the brackets to mount the passenger side battery tray and another one just like it on the driver’s side. A/C MANIFOLD This A/C manifold bolts to the back of a 1994 and newer Dodge A/C pump, making the A/C plumbing less of a challenge. All you will need to do is have some new hoses crimped between our manifold and a 1999 style A/C tube at the drier (a picture of one is in our manual), and the stock line connected to your condenser. RADIATOR HOSE KIT Our radiator hose kit includes the radiator and heater hoses that work well in the conversion and a specially bent aluminized steel lower radiator hose connector tube along with hose clamps. The kit that is offered in our kit builder for these trucks only works with the stock radiator and a new style water connections as shown on our Cummins Engine Information page. WIRING HARNESS SERVICES CPP can provide you 5.4 or 6.8L engine harness modification services that make wiring much less of a challenge. We modify your Ford engine harness to connect to a Cummins engine harness, providing your Ford PCM the signals it needs to make your factory gauges work. This service is normally included in packages for those using the 2003 and newer Common Rail Cummins engines, as we do not provide wiring instructions for do-it-yourselfers for this specific engine. This service is optional for the 12-Valve and 1998½ - 2002 24-Valve engines, as we do provide wiring instructions for these engines when you buy parts for your conversion. PARTS YOU WILL NEED TO GET ON YOUR OWN Even if you buy everything we offer for your truck, you will need to come up with a few parts on your own, such as an exhaust down pipe (usually a Dodge down pipe can be a good start), a diesel exhaust system for the same year and style of your truck, a 2008-2010 Ford Super Duty diesel radiator and intercooler, and intercooler tubes (again Dodge stuff can be a good start). We may be able to supply you with these, but our supply is limited at this time. If you live in a colder climate, we would also recommend adding an additional battery for longer starter cranking ability. Automatic transmission equipped trucks will require a throttle position sensor. Depending on the year and what transmission your Cummins engine had on it originally, you may need to purchase a throttle position sensor, or look into other options. All 24-Valve engines already have a throttle position sensor that can be used for the transmission controller. Sometimes customers buy engines out of industrial applications. These engines may not have the correct brackets for conversion friendly accessories. See Cummins Engine Information for more information.

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