Ford Cummins Swap Problems – Some Unconventional Swap Ideas

The Cummins engine is known for its power, reliability, fuel economy, and durability. So, if you are looking to get the best engine for your heavy-duty truck with all those factors in check, you'll hardly go wrong with it. These things also make it great for engine swaps, especially in different Ford vehicles.

What could definitely go wrong with it? It turns out that there are a lot of risks associated with Cummins swap into your Ford vehicle. Let's put on our detective hats and investigate the possible problems that may occur should you ever decide to proceed with it. And, if you think the benefits far outweigh the risks, we have included here some crazy swap ideas that will keep you going.

What Could Go Wrong in a Cummins Swap?

As a word of advice, you should familiarize yourself with the risks first before even trying to do anything with your Ford vehicle. These nuggets of information will aid you in deciding whether the Cummins swap is worth the trouble or not. Should you ever proceed, these will still be helpful in preparing you for any hiccups that you might encounter along the way.

With that said, here are the things that you may contend with when doing a Cummins swap:

1. Prepare to Lose Your Warranty

Automakers frown at the idea of putting aftermarket mods in their vehicles because it alters their intended design and purpose. Aside from that, it compromises performance and safety, particularly when talking about unauthorized tinkering with the engine. So, don't be surprised if you find yourself losing your warranty and Ford's service center will be refusing to work on your auto ever again.

2. You Risk Breaking State Regulations

Although you won't be jailed for simply swapping your Ford engine for a Cummins, you will certainly face sanctions for breaking emission regulations, which include a hefty fine of around $10,000 or more depending on the laws imposed by your state.

If by chance your modification or engine swap is not up to the required standards in your state, your vehicle registration could be declined, too. Now, here is where it gets tricky because if you go on and drive your auto on the road anyway and you are caught numerous times, that's the time when you could face jail time or the revocation of your driver's license. Things could easily escalate from bad to worse if the modification you made has caused a serious accident resulting in serious injuries or fatality.

3. It's Expensive

A Cummins engine costs $5,000 to $10,000. Including labor, the expenses of an engine transplant could balloon somewhere between $15,000 and $20,000 depending on the customizations required to accommodate the swap.

4. ECU Faults

When performing a Cummins engine swap, the ECU will need to be reprogrammed (or better replaced) to accommodate the new engine. This is because the ECU controls many of the engine's functions, such as ignition timing, fuel delivery, and emissions control.

Without proper programming, the engine may not run correctly or may produce excessive emissions. You will be alerted with numerous errors along the way, too. Therefore, it is important to make sure that the ECU is properly programmed before attempting to start the new engine.

5. You Quicken the Vehicle's Overall Wear and Tear

Ford models today are packing plenty of tech to optimize their performance, fuel economy, safety, comfort, and others. Your stock engine is designed to work in harmony with them plus the overall design of your vehicle. A Cummins engine swap is an intrusive process that requires extensive modifications for it to work well with the other moving components of the donor vehicle.

A high level of expertise is needed if you decide to swap your Ford engine for a Cummins. Depending on the model of the recipient vehicle, the swap may require further modifications to the radiator, fuel system, intercooler, and drivetrain. It may necessitate adjustments on the intake and exhaust manifolds, water pump, pulleys, and brackets on the Cummins as well as the synchronization of its operation with the other key components of the Ford vehicle.

Moreover, there's the potential for decreased fuel economy and increased emissions with a Cummins-swapped Ford. Bear in mind also that the resale value of a Cummins-swapped Ford may be lower than that of a stock Ford unless you find an interested buyer who really digs engine swaps.

With these things out of the way, are you still going for it? If the answer is yes, check out the next part for the crazy swap ideas that you can emulate in your Ford auto.

Unconventional Swap Ideas

Why would you even want to risk everything for a Cummins swap? For hardcore motorheads, there's a wide array of benefits waiting for you if you're up for the challenge.

As mentioned earlier, the Cummins engine showcases power, dependability, fuel efficiency, and longevity. This is why it is among the most beloved crate engines out there and people would willingly go through with all the trouble of swapping their Ford engine with it.

First off, the factory setting of the Cummins provides at least 370 hp and 850 lb-ft of torque that can be further modified to astronomical levels when tuned. Second, it provides enough power to tow immense trailers. Third, it is frugal with an estimated 15 mpg combined fuel consumption or even 22+ mpg with the proper setup. Lastly, its durability can go north of 350,000 miles with proper maintenance and without mods.

There are some noteworthy tuners who achieved great strides in engine swapping the Cummins to a Ford vehicle over the years. This part revisits some of their works so you will get an idea of the potentials you can unlock when swapping a Cummins over a Ford.

1. Previous Generations of the Ford F-Series with Cummins

There's a significant number of people already who have swapped the stock engine of their old F-Series trucks with a Cummins. Most of them would reason out that it is for the power gain and bragging rights.

The Cummins engine is significantly more powerful than the stock Ford engine of the old generation F-Series. Combined with your old Ford heavy-duty pickup, you'll be able to tow and haul much more weight with ease. You may also notice an improvement in fuel economy, as the Cummins engine is very efficient. Plus, you'll get the satisfaction of knowing that you have a unique truck with seriously impressive power.

2. Ford Mustang with Cummins

As the old saying goes, there's no replacement for displacement. But in the case of the 12-valve Cummins diesel engine that powers Westen Champlin's 'Smokestang' Mustang, there might just be an exception to that rule.

Champlin's Mustang is powered by an inline-six Cummins engine, which he sourced from a donor truck. He then had to do some serious fabrication work in order to make it fit into the engine bay of his Mustang, including custom motor mounts and a set of adapters that allow him to use the new transmission.

The end result is a 1,000-hp beast of a car that can smoke its tires at will and sounds absolutely incredible doing it. We have to say, we're impressed with Champlin's handiwork because he managed to stuff a massive diesel engine into a relatively small space.

The stock engine of the donor Mustang, a Coyote V8, was reportedly scrapped prior, so Champlin decided to go bananas with the car as it had nothing more to lose anyway.

3. Freightliner Truck with Cummins

Freightliner trucks are already a relic of the past. These cab trucks were produced by Ford before they were rebranded as Sterling Trucks under Daimler-Benz's acquisition in 1997.

If you are planning on restoring a Freightliner and you decide to snap a Cummins with it, expect to see an increase in power. The Cummins engine is known for its high output and reliability, so swapping it into a cab truck should give you a noticeable boost in performance.

There are a few things to keep in mind when doing this swap, however. First, the Freightliner truck will likely need some modifications to accommodate the larger engine. Secondly, you'll need to make sure that all of the engine's accessories are compatible with the truck. But if you do your research and plan ahead, an engine swap like this can be a great way to get more power out of your truck as you put it back into running condition.

To Swap or Not to Swap?

As shown here, a Cummins swap will certainly work wonders for your Ford heavy-duty pickup, cab truck, or muscle car. This will surely elevate their game thanks to the Cummins' extra kick in power, fuel economy, and long life. However, it is important for you to assess your options first by utilizing all the information presented here so you will understand the risks should you ever proceed with it like loss of warranty, a possible run-in with the law, expensive works, ECU faults, and quick wear of the donor vehicle.