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jt2016

Ford F250: Changing the 460 Gas Engine to a 7.3L Powerstroke Diesel

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for starters I was inquiring about swapping the gas engine i have in my 1996 ford f250 crew cab and putting a 7.3 turbo diesel in it,i currently have the 460 big block in it now and don't think that i will have any issues pulling the 460 out and swapping it for the 7.3. i would also like to put a manual transmission in it, and just wanted to cover my bases before i dive into tearing it down. any advice is helpful

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Welcome to the forums, jt2016!  The swap is possible, though I would ask whether this truck requires emissions inspections.  If so, the swap would require an engine the same year or newer than the chassis and the use of any/all emission related chassis or engine parts considered part of the 1996 7.3L Powerstroke package.

If I were doing this swap, including the engine and a manual transmission, I would seek an intact donor vehicle for the prototype.  You want to compare any and all components that make up the difference between the engine and transmission packages.  This could be considerable work, and you need to verify items like the fuel pump, fuel lines, mounts, the exhaust system, any cooling system/radiator needs, essentially a side-by-side comparison of parts.

With the manual transmission conversion, there's the steering column if you want to get rid of the column shifter, the pedal mechanism for the clutch/brake, any wiring differences between the 7.3L diesel and the 460 gasoline engine (EFI) and so forth.  The main concern would be sensors and wiring harness differences underhood, plus the ECU and the fuel pump. 

I've considered a manual transmission swap with our 2005 Dodge Ram.  In hindsight, I'd have preferred a 6-speed manual transmission over the 48RE automatic.  However, the task of changing out the transmission, flywheel and clutch parts, accounting for all of the chassis, steering column and other differences, would likely have me weighing the sale of our truck and purchase of a manual transmission model in identical or similar condition...In real terms, your proposed project contains many of these challenges.

Happy to provide illustrations of parts if a specific question comes up.  The diesel engine chassis is simpler than the gasoline models as a whole.  The kicker might be your desire to change the transmission, although I applaud that notion.  As a footnote, you need to consider the spring rates for the front springs of a 460 versus 7.3L model.  As heavy as the big-block gas engine is, the 7.3L Powerstroke could be heavier!

Moses

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