Efi to mfi

[callahan347]

I have a 99 one ton dually 6.5L the body is shot. I would like to put the 6.5 in a deuce and a half military truck with a gas 6 cylinder in it. From what I've read the easiest way to do this would be to swap to mechanical injection. What do I need to replace other than the injection pump? And what electronics do I need to salvage from the truck?

[Robyn]

Hello

Welcome to TDP

The engine is the same pretty much across the board.

You will need the following.

Mechanical injection pump from a 1992-1993 6.5
If you can't find a 6.5 pump...you can use one from a 6.2 and turn the fuel screw up some.

You will need the Short injectors from the early 6.5 (92-93) or a late 6.2

***The mechanical pump engines use a lower pop pressure injector.

You will need a matching set of fuel lines from the early 6.5 or the late 6.2 (IP TO INJECTORS) as the electronic systems use a different line fitting at the IP end on the DS4 Electronic pumps

You will need to fashion your own wiring to run power to the IP (Red wire...fuel solenoid on/off)

Also you will need a switched (from ignition) a 12 volt supply that runs through a 125 F normally closed temp switch (open on temp rise) to feed the COLD CASE ADVANCE solenoid and the fast idle

The earlier 6.2 used the thermal switch to control the Cold advance and hi idle and the switch screws into the rear of the RH head just aft of the exhaust manifold.

Wire up a Ford starter relay to power your glow plugs and use a momentary button to operate (USE 60G GLOW PLUGS) 10-15 SECONDS should lite it fine...

Use a suitable electric fuel pump with 5 psi max pressure at the IP inlet..

Be sure to set the pump up with a relay and such so the pump does not operate if the engine is dead (Crash safety thing)

Use a Racor fuel filter with water separator (2 micron is great) Filter needs to be able to pass 40 gph...as does the pump.

Be sure your system has a fuel return from the injectors and IP back to the tank.... must have this..

You can use an appropriate sending units to make the gauges in the deuce happy.

Coolant temp
Oil pressure

Use a mechanical "Turbo master" ...spring waste gate management system to control the turbo

15 psi MAX
1000 F Exhaust gas temp at the manifold outlet under hard load..

You will need a fairly hefty radiator to deal with the heat the 6.5 builds.

This should get you well on your way.

What sort of tranny?????

If you go with a TH-400 Auto ...there is a vacuum valve that will fit the IP to run the vacuum from the engines vacuum pump and control the shift points.. (DELCO #14057219) Early GM manuals will have the tech on adjusting the valve...(Real low throttle = high vacuum 26"hg....hard on the throttle and the vacuum will be much lower. (This setup sort of tries to look like what a gas engine produces) be sure to use a diesel vacuum modulator for best results)

Stick shift...no worries, nothing needed.

Electronic box like a 4L80... Use a stand alone controller with its own equipment.

[callahan347]

Thank you for the help and yes th400 trans and more than likely will have manual valve body.

[Robyn]

The manual 1..2..3 VB will make things simple.

What year of Deuce ???