It’s not hard. I did a 97 351W to 7.3 about 15 years ago. Mine was a ambulance so wiring harness was harder and converting the trans to 4/4 was not supper fun. I would add a IC while it’s apart. I did a 6.0 IC and it fit nice and was dirt cheap.

 

That is awesome, seems like patience is the key. On your swap, did you use the 351w truck's gas tanks? I have heard something about the gas truck tanks being galvanized and that putting diesel in them is a bad idea.... rumor or fact?

The rolled donor truck has a 444Fab fuel system with SD Bosch fuel pump. It has a sump on the front tank, and the rear tank is not plumbed in at all.... ideally id like to use both tanks on the final product, though.

For the transmission, If I understand correctly, I just need to switch tailshaft housings and completely disassemble the 2wd and swap in a 4wd output shaft.

The donor truck I picked up is a XLT, with same bed/cab configuration, but 2wd, with power mirrors and a key fob. My truck has a manual shift transfer case, so I think most of the wiring should switch right over. I have been looking at the 6.0 intercooler, and that seems like the way to go. I wish I could put one together while I have everything apart, but the financial priority is to get the baselines covered, then start building it up later.

 

Trans output shaft is first in last out so full disassembly of the transmission. You are correct you just need the 4 x 4 output tail housing and it all goes together. I did use the gas steel tanks gutting the electric fuel pump inside and just lengthening things to reach the bottom and moving the return away from the pick up. I did end up buying a piece of stainless tube and bending it for the supply line to the engine . But I think that was just for peace of mind with the modifications I plan on doing to the truck. It had larger injectors the IC and tune.

 

On the weekend and over several nights this week, Basically anything useful on the donor truck has been removed or sold.
one of the Highlights was a rounded off bolt head on the rear of the turbo pedestal.

A few more details on the donor truck:
The Cali-emissions donor truck ran and drove, but smoked quite a bit of eye-stinging whitish smoke that cleared up on the test drive. The truck had sat for 1 month since the accident where it had been driven by a teenager too fast around a corner, tipped over and scooted through a potato field on its lid. They tipped it right side up, started and ran it for a bit then drove it a quarter mile home and parked it. I was the first person to start and run it 1 month later. When we got home, I started and ran the truck again. The longer it ran, the more whitish nasty smoke it produced. The people I bought it from had owned it for only a few days before it was wrecked and knew nothing of its history. I found a invoice with a phone number in the glove box, and got in contact with the previous owner who had the truck for 7 years prior. He told me that the injectors, turbo, and transmission were all original. (truck odometer reads 273,000) he had replaced glowplugs, upgraded glowplug relay, installed a 6637 air filter, the 444Fab fuel system, and a PHP Hydra chip( that was on a daily tune when I started the truck). The truck has ZERO vapor or pressure coming out of the oil fill hole when I went to look at it, and i noticed both a bad leak at the oil cooler fittings and a wisp of oil in the coolant overflow reservoir. When I drained the oil from the engine, no water/coolant came out first.

My initial thoughts include:
-possible cracked injector cups from probably running on its side for a bit (due to aftermarket fuel system with no shutoff switch) might let coolant in?
-compromised oil cooler o-rings allowing oil into coolant?
-old stock injectors due for replacement?
-likely worn out turbo.
-massive amounts of soot on the firewall, broken bolt head on rear of driver exhaust manifold, (original seal with no exhaust gaskets) would manifolds need replaced, just broken bolt replaced, or just gaskets installed?

My engine plan of attack:
-bellowed up-pipes
-new injectors (single shot 175/146), injector cups from riffraff (stock or stainless steel worth it?)
-EBPV delete for now, then upgraded turbo once I sell the 460 drivetrain
-cooling system rebuild, 6.0 fan
-lower end gasket set
-not remove the heads at all, (plan do do head studs one bolt at a time down the road)
-resolve exhaust manifold leaks (not sure what to do yet)
-install aftermarket downpipe
-new engine intake boots
-new engine mounts

transmission plan of attack:
-rebuild kit
-4x4 filter/pan (upgraded pan to make trans housing more rigid from MTS Diesel?)
-triple disc TC (looking at roadrunner torque converters in phoenix, AZ)
-billet input shaft
-4x4 tail housing and output shaft
-upgraded valve body (MTS)

HP hopes:
325-400 HP
-I found a set of 175/146 Swamps single shot injectors locally, brand new never installed.
-looking at the KC300x turbo with 1.0 AR housing (down the road)
-TS 6-position chip (personal preference)

 

So did you ever finish your swap? I’m getting ready to start my 460 extended cab swap for my 7.3 single cab motor and looking for any input I can get. Both are 95s, gasser is extended cab 4x4 , psd is a single cab 2x4. What do I need to be aware of when going into this?

 

Hey! YES YES YES, I mostly transferred everything over to instagram after starting the swap, and you can see the whole swap start to finish there. In summary, the swap was really easy with the donor truck, and I have been happily driving the truck as a diesel since last june. it runs great and the power change is phenomenal. check out my instagram @CowboyCustomDiesel. I have also started making a few custom parts for these trucks such as customizable core support lower valances, they can be found at www.cowboycustomdiesel.com. I converted the 2wd donor diesel transmission to 4x4 in my driveway and there is a post specifically about that on instagram, but i am happy to cover that more in depth too. if you have any questions, just ask!

 

I like these custom parts you are making.

Just kidding my man, congrats on the business this is a great display idea

 

The website is pretty cool. Your truck in the background with the scenery is looking good!