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Discussion Starter #1
Long time lurker, first time poster. Been reading through a lot of older similar posts on both this forum and many others. Found one on Pirate 4x4 that was helpful, but I wanted to see if anyone here might be able to help.

Here's the VERY basics. I want to take the entire drivetrain (engine, tranny, transfer case, intercooler, cooling system, etc.) out of this 2004.5:
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And put it into this 2004 Bigfoot Class C:
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Now, I know it CAN be done, I just want to know what kind of nightmare I'm in for. I've read many different E Series conversions, and have talked to MGMETALWORKS in Oregon about his 6.7 his dropped in an E350. Also, I plan to eventually convert the motorhome into a 4x4 using the UJoint Offroad conversion. It looks like the Dodge transfer case output shaft and the SuperDuty front axle have the front drive shaft on the drivers side. Plus, I made sure that the Dodge I picked up has the electronic shift transfer case, so no having to hog a hole in the floor of the motorhome for the shifter.

Here's what I know so far. Diesel Conversion Specialists sell motor mounts, but thats about it. I think they also said I can send both the wiring harnesses off to them so I can have them work together. Other than that though, a lot will be custom, including the rear tranny and transfer case mounts, drive shaft, etc.

I also plan to do a very mild build. I installed a set of 30% over injectors on my early 04, and it made a pretty good difference. I plan to do the same here, but I also plan on installing a 2nd gen manifold kit so getting the downpipe in will be easier, and hopefully not run into the doghouse. I don't plan on doing any other motor mods; my goal is RELIABILITY and FUEL MILEAGE.

Along with that, I need to rebuild the tranny to match. My early 04 is the NV5600, so working on the 48RE is pretty foreign to me. I need to find out what I need to make it reliable, and able to take the weight of the motorhome. Also, where in WA could I take to get it rebuilt and NOT cost a fortune.

My biggest hangups right now are all the ancillary components; power steeting, brakes, A/C, cruise control, and the BIGGEST part, which will be the wiring to make it all work together in the Ford Chassis.

I haven't started the swap yet, at this point I'm acquiring as much info as I can before I make the leap. I've wrenched on Dodge Diesel's for years, but have never done a swap. Is this going to be a nightmare? All suggestions are appreciated! Thanks!!!
 

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Talk to dynamic transmission about your 48re. Good company in Washington.
 
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If conversion motor mounts and wiring harness work are available, someone has done this swap. Diesel conversion specialist are great to work with. I have used them many times in the past for oddball or unique stuff I was building. Call them and just ask if they can put you in contact with someone who has done it. You might be surprised.

Other than that I think you're on the right road and my advice is always to eat it like an elephant. One little bite at a time. Get it in there and start working out the details as you go. Don't be scared to yank it back out to work on a small detail. Do it right the first time. Transmission/ transfer case mounts are easy to build, driveshafts are made custom every day. Tom's driveshaft can help you with that and you'll have it in 3 days. A 4x4 diesel conversion RV would be cool.
 

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Discussion Starter #5
Thanks guys! I guess I should have posted this in the 'Swaps' forum, I actually didn't even know about it until rghavana just mentioned it. I spent most of the morning looking through some pretty cool swaps.

And Trev, thanks for the recommendation! I'll check them out!

One thing I've actually been wondering, is would I be better to try to use the factory dodge harness, or use standalone harnesses for the engine and tranny? And if I do that, will I still be able to get all the other factory Ford stuff to work? Since this IS a motorhome, I plan to be travelling a lot in the summer. Meaning that cruise control and A/C are going to be a big deal. Will it be difficult to get all that working together?

I was also thinking about the gauge cluster, and that it might actually be easier if I can figure out a way to swap in the dodge gauge cluster into the Ford. Maybe?

Thanks again guys!
 

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Cluster will be nightmare, electronic transfer case will be nightmare.
I would be looking to see what OEM Cummins/Ford parts you can use.
 

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Wiring shouldn't be a problem. DCS and other companies have harnesses available. It's the ability to cool the various things that would be hard to cram in there. Radiator, charge air cooler, A/C, etc. I want to do this exact swap for my 08 E450 thats 31' long, and has the v10. I miss the torque of the diesel. I will have to live vicariously thru you as I have several other irons in the fire.
 
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Discussion Starter #8
I talked to DCS a while back. They said they had plenty of harnesses available for the trucks, but the vans were a different story. It sounded like if I sent them both harnesses, the one from the van and the one from the truck, that they would be able to make they work together.

I would REALLY like to take the instrument cluster out of the truck, and make it work in the van. I think that would make a lot of the instrumentation a LOT easier; Tach, Wait to start light, etc.

The biggest thing I miss, is fuel mileage. The V10 gets 7-9, and thats on a 55 gallon tank. I anticipate if I can do the mild build I'm hoping for (30% over injectors), I should be able to get around 14-16 mpg, even in the motorhome. At that point, I worked it out that if I drive the motorhome for a minimum of 80k miles, which I plan to do, the conversion will have paid for itself. Well, monetarily... Chronologically might be a different story...
 

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What Ford transmission does it have in it right now?
 
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