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Ford Excursion cummins swap (HPCR & 48RE)

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Ford Excursion cummins swap (HPCR & 48RE)

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Old 12-25-2009, 06:27 PM
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I am having the same problems as 5.9 .I have installed a 2003 CR in a 93 1st Gen. It is a short bed 4X4 with 410's and 35's. I used a painless wire harness. I have nowhere to hook up the VSS wire. I believe I am having the same problem with fuel pressure. I also had the rattle noise . My truck is a diesel cab. My 05 does not have this rattle and my clatter box 92 is quieter on the throttle with a load. There is deffinately a problem and noises that are not normal as comparing it with my other Cummins trucks. So far I installed the bully dog from my 05 didn't help. I put a BD Diesel boost fooler on and the rattle went away but. The truck has no power compared to my 05 and no smoke not even on crazy larry. How does the VSS control the fuel. I used the complete driveline from the 93. The rear diff in the truck is from an earlier year without a counter. The harness is stand alone from painless and uses a 2003 6 spd manual ECM. I had it flashed to remove sentry key anti theft. The truck runs and drives but it is not what I thought it would be. I installed a 66 mm turbo and a 5 inch exhaust. ats manifold, Banks intake, fass lifter pump, and a large Power stroke intercooler. It blows the tires away when you nail it at a dead stop and smokes black. But then the smoke stops it falls on its face and pulls about like my stock 92. If the truck wouldn't be so light it would be a real dog. The motor is New with approx. 1600 miles. Trans is a 46rh. no controller needed. There were several open ended wires not used. 1 VSS, 2 Cruise, 2 Brake switch, and electric fan plug. I have 2 codes 1652 short to ground in the J1850 circuit. and 2127 undefined. any help would be appreciated My 1st gen runs as good as this conversion. my 05 is a powerhouse. There must be somthing missing in the electronics that the ECM needs to see. Does any one have any ideas. Thanks Steve
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Old 01-24-2010, 08:39 PM
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Question Ford Excursion 5.9 swap (wiring and t-case question)

Excursion looks great! I have a similar project and was hoping I can get some information from you. I have a 92 5.9L and a 47RH that I am putting into a 99 Ford F250 SD 4X4. I was planing to use the Dodge T-case (Dodge 241 DHD), but may use the Ford after seeing your conversion. I am curious how you got the Ford transfer case to work with the Dodge transmission and how did you wire the 5.9 into the Excursion harness. I have a factory service wiring manual for my truck, but not one for the 5.9. I have been able and want to use factory parts as much as possible, so I can keep costs down and not have an issue with finding replacement parts. My email is [email protected]. THX
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Old 01-25-2010, 11:24 AM
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Originally Posted by bargaineer07 View Post
Excursion looks great! I have a similar project and was hoping I can get some information from you. I have a 92 5.9L and a 47RH that I am putting into a 99 Ford F250 SD 4X4. I was planing to use the Dodge T-case (Dodge 241 DHD), but may use the Ford after seeing your conversion. I am curious how you got the Ford transfer case to work with the Dodge transmission and how did you wire the 5.9 into the Excursion harness. I have a factory service wiring manual for my truck, but not one for the 5.9. I have been able and want to use factory parts as much as possible, so I can keep costs down and not have an issue with finding replacement parts. My email is [email protected]. THX
You will have much less wiring to do then he did on his excursion. All you need is 12v power to the IP. A few more wires if you keep the fuel heater and the air intake heater. Of course you will also need to wire in an old voltage regulator to control the alternator.
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Old 01-25-2010, 11:41 AM
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Thanks, for the replies...I think providing power to the I/P,alt,starter, etc will be pretty straight forward but I was hoping to use the two electical connectors on the end of the CTD and wire them either into the F250's fuse box or harness. I want to maintain the stock guages/lights and have it work and look like it came from the factory as much as possible. There are 3 large electrical connectors (I thought I could use) that lay on the driver's side fender well--but when I looked at them yesterday, they appear only to send power and control the old transmission/t-case, fuel tank, fuel pump and rear lights. Does anyone know if there is a harness that I can splice into, or do I need to go to the fuse box? Is there a simpler way that I am not thinking about?

Last edited by bargaineer07; 01-25-2010 at 11:49 AM. Reason: Added more info for clarification...
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Old 04-23-2013, 06:19 PM
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Originally Posted by 5.9Excursion View Post
I haven't actually done the splicing yet. It's somewhat complicated how the AC lines will get done. My local shop that can crimp the connections uses fittings that crimp to a hose on one end and use a compression fitting on the other... So it isn't like a factory hose, I would think the compression fitting may leak?

So I spoke with a shop that can weld aluminum. He can butt weld the lines together for me (but will take some work since the weld will be close to the hose and aluminum dissapates heat very very well).

I trial fitted the dodge line in and since I clocked my turbo housing to better fit the engine compartment, the intercooler line hits the AC line. So I officially decided to wait until spring to work on that portion. It's so stinkin' cold...

Regarding the wiring, you would use the ford wiring and splice the dodge plug onto it in place of the ford plug. You have to get the wires correct or you will toast the diode (I was told anyways). I haven't looked into it yet. The pressure switch unscrewed from the ford line and screwed right into the dodge line.
Did you ever get your A/C lines done? Also, any luck on cruise?
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Old 12-15-2014, 03:59 PM
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Here it is today. I'm just about ready to put it up on Craigslist for sale if anyone is interested.

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Old 12-15-2014, 04:24 PM
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cool. any videos of it running?
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Old 12-22-2014, 01:10 PM
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Is the truck still for sale?
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