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Discussion Starter #1 (Edited)
Hello everyone, time for you to hate me >:) :rofl: >:) I'm swapping a 5.9 CR into a 2003 6.0 Ford Excursion. I tried to love the engine but after the 2nd blown head gasket in 2 years and the last few years it's had constant problems so I decided it was time for a change.

Little bits of information

My dad bought the truck new in 03
Liked the performance the modified 6.0 had
Doing the swap in a friends barn
It's hot in South Houston right now
I've never done anything like this before but my dad likes to wrench on things and a friend of mine is in school to become an aircraft mechanic.
If there's a part you want ask if I don't need it it's going to need a new home.

5.9 Engine
03 coated piston
BBI stage 2 Injectors
S362 and S475
ARP 625s
06 ECM + EFILive
Repinned painless wiring harness
Fleece coolant bypass
Gulf Coast bypass filter

6.0
ARP studs
OEM gaskets
155/30 Injectors
KC stage 2 turbo
SCT tuner with several custom tunes
BPD 58V FICM
Diesel Site HPOP and water pump


Truck
Limited
V code springs in the front
3" lift
OEM Platinum 20s
35" tires


I know I'm forgetting stuff

This is the last picture I took before I started pulling things apart. I just pressure washed the underside and engine bay (I found out later not very well). I also found out I suck at taking pictures a lot I'm posting don't look great.

That car port in the back I was originally going to A/C but the small window unit I had didn't make much of a difference and I was in and out of it so much it wasn't worth it. I kept the car port up because the barn has small leaks and it works like an air tunnel forcing more air under the truck which was nice when I was under it.

Heres the engine before it was pulled (I didn't pull it)


Just got it home


Getting ready to wash it off for the first time (the axle is for another project)


A little cleaner


Some wiring work


Front ends off


Big fan my friend


Found a place for my old Powerstroke sticker >:)


Turbos gone


Intake and up pipes are gone they were a pain


Almost ready to pull


Ready to pull


6.0 IS OUT!!!


I had air tools until a few days ago when this guy decided it wanted to be an internal combustion engine :crying:
 

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What about that friggin Huricane man???

k
 

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Discussion Starter #3
What about that friggin Huricane man???

k
Nothing bad so far just wind and rain I pulled the engine this morning and everyone I've talked too was surprised I was working on it
 
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Discussion Starter #5
Will do....
 

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Fuel it up again Dummy
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I'm gonna say it........................should have o-ringed those heads. But a little late for that.


That said I'm sure your going to have a nice ride. Will watch you go at it :thumb:

I did just notice its a Excursion and you have the swash plate pump and all first production......I get it. I'm all in that thing is gonna be unique for sure. International with the help from Ford sure laid an a egg.
Can't say our engines ain't famous, too bad it's for all the wrong reasons :(
 

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Discussion Starter #7
Not much happening today I'm still safe and dry but there's flooding all around me.




I'm gonna say it........................should have o-ringed those heads. But a little late for that.


That said I'm sure your going to have a nice ride. Will watch you go at it :thumb:

I did just notice its a Excursion and you have the swash plate pump and all first production......I get it. I'm all in that thing is gonna be unique for sure. International with the help from Ford sure laid an a egg.
Can't say our engines ain't famous, too bad it's for all the wrong reasons :(
I found out about O-rings after it was built and it's a big regret not doing them. It's definitely an early 03 if there was ever anything written in instructions for something that said in "extremely rare circumstances" I had to do it.
 

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KCCO
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I'm still having fun with my 6.0 but when it finally bites the big one, I'm pretty sure I'm going to go down this route as well. I'm definitely gonna love it until it dies though.

Good luck with the project and I can't wait to keep reading an seeing updates!
 

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I'm gonna say it........................should have o-ringed those heads. But a little late for that.


That said I'm sure your going to have a nice ride. Will watch you go at it :thumb:

I did just notice its a Excursion and you have the swash plate pump and all first production......I get it. I'm all in that thing is gonna be unique for sure. International with the help from Ford sure laid an a egg.
Can't say our engines ain't famous, too bad it's for all the wrong reasons :(
o-rings don't save everyone...
 

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Fuel it up again Dummy
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o-rings don't save everyone...
LOL

Well the ducks have to be in a row for anything to work. Even with them properly done the six liter engine is not one to push for big power. Mainly because their piles of
sh-it from the get go. Ford did their job on the truck and it got better as time went on. They should have honestly took on designing their own when the EPA mandated the diesel engines to pass a standard of set emissions. Same with GM why in the hell are they paying the Japanese for engines. I just don't get it, Cummins is in a different situation in my mind. They have more experience than anyone because they have engines all over the place. Big GIANT ones in all the trains along with lots of generators for gads of the commercial buildings in California as well. They have it pretty much figured out. Pretty amazing that Dodge struck a deal with them long ago and has been the main stay of the Dodge trucks.
Nobody is going to give anyone grief for owning a Cummins powered truck.lol

I saw that PowerStroke Help guy state the new 6.7 Power Strokes are crazy clean out the tail pipe. He said it takes 90 6.7 trucks to equal the emissions from one 7.3 engine. That's mind bending. That said anyone including you tossing in a Cummins into the old Ford is going to have one dependable truck.

Good Luck to both of you.
 

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Discussion Starter #11
I saw that PowerStroke Help guy state the new 6.7 Power Strokes are crazy clean out the tail pipe. He said it takes 90 6.7 trucks to equal the emissions from one 7.3 engine. That's mind bending. That said anyone including you tossing in a Cummins into the old Ford is going to have one dependable truck.

Good Luck to both of you.
It's not that big of an amazement to me a big chunk of pollution was just shifted from the tail pipe to the chemical plants that produce DEF.
 

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LOL

Well the ducks have to be in a row for anything to work. Even with them properly done the six liter engine is not one to push for big power. Mainly because their piles of
sh-it from the get go. Ford did their job on the truck and it got better as time went on. They should have honestly took on designing their own when the EPA mandated the diesel engines to pass a standard of set emissions. Same with GM why in the hell are they paying the Japanese for engines. I just don't get it, Cummins is in a different situation in my mind. They have more experience than anyone because they have engines all over the place. Big GIANT ones in all the trains along with lots of generators for gads of the commercial buildings in California as well. They have it pretty much figured out. Pretty amazing that Dodge struck a deal with them long ago and has been the main stay of the Dodge trucks.
Nobody is going to give anyone grief for owning a Cummins powered truck.lol

I saw that PowerStroke Help guy state the new 6.7 Power Strokes are crazy clean out the tail pipe. He said it takes 90 6.7 trucks to equal the emissions from one 7.3 engine. That's mind bending. That said anyone including you tossing in a Cummins into the old Ford is going to have one dependable truck.

Good Luck to both of you.
I wouldn't trust that PowerStroke Help guy as far as I could throw him. probably no actual evidence behind the claim
 

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Fuel it up again Dummy
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I wouldn't trust that PowerStroke Help guy as far as I could throw him. probably no actual evidence behind the claim
I was sure to say where that info came from. I get a kick out of the guy myself. He has gotten better with time I think.
He's alright............ I decided to cut him some slack when he said the 6.0 was actually a good engine if you update it and treat it right.

Junior125 I got to ask you who is the Cat in your Avitar ? I think of you as a early priest every time I see your posts. LOL No kidding ;)
 

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AMERICA!
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@junior125 a priest??? Now that's funny... :hehe:
 

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I can't say I haven't thought about doing this swap myself.

My big concern with this swap always comes down to transmission tuning. Do you use a stand alone unit or the pcm/ecm with custom tuning? Seems like it's a mixed bag, or that's majority of what I read.
 
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Discussion Starter #16
I can't say I haven't thought about doing this swap myself.

My big concern with this swap always comes down to transmission tuning. Do you use a stand alone unit or the pcm/ecm with custom tuning? Seems like it's a mixed bag, or that's majority of what I read.
For the 5r there's aftermarket controllers and the OEM TCM as of right now the 6.0 TCM is the best. Another option would be to swap to a different transmission, I really would like a 6r140 but since there's no current way to control it the Allison 6 speed is probably the next best.

I have a friend trying out Home | Transmission Tuner if it goes well I may use him too but I have been thinking about asking Gearhead if they would tune it since I liked there shifting the best out of the custom tuners I've tried.
 
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I feel pretty well invested in the 5r110 at this point.

What made you choose the 5.9 vs the 6.7?
 
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Discussion Starter #18
I feel pretty well invested in the 5r110 at this point.

What made you choose the 5.9 vs the 6.7?
After some research, I found the 6.7 throws rods and blows head gaskets easier than the 5.9. From what I found the longer stroke of the 6.7 increase the angle to the point they snap easier, there are 2 fixes billet rods ($$$) or swap a 5.9 crank in then the 6.7 becomes a 6.4.

I didn't want to go from one engine that had problems to another and seeing how the 5.9 wasn't as susceptible to those failures I picked it (yes they have their own quirks).
 

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I knew about the head gasket issue but it seems to be cured with a set of 625s. I didn't realize that they liked to eject rods. Obviously the 5.9 is plenty capable. Nothing is without it's issues. I really enjoy watching these builds though.

I can't tell you how many times I have gone back and forth between the swap and rebuilding my motor now.
 

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Discussion Starter #20 (Edited)
Heres an update on the progress

Dropped my fuel tank which wasn't hard at all until it slipped off the jack



Removed the drivers and passengers battery trays





Pulled the torque converter



First layer of engine paint final coating will be Ford green





For some reason, my frame doesn't have the pre drilled holes to move the transmission cross member back. I'm thinking about making a new transmission support mount that will move it back the desired amount instead since my original one doesn't look right to me.



 
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