Swapping a 6.7 Cummins into a second-generation Dodge Ram is a popular modification among enthusiasts seeking increased power and reliability. This comprehensive guide delves into the complexities, benefits, and considerations of this demanding project. We'll cover everything from initial planning to final adjustments, ensuring you're well-prepared for this ambitious undertaking.
Why Swap a 6.7 Cummins into a 2nd Gen Ram?
The allure of the 6.7 Cummins is undeniable. These engines boast significantly more power and torque than the factory 5.9 Cummins found in second-generation Rams. This translates to a dramatic improvement in towing capacity, acceleration, and overall driving experience. The 6.7 also offers advancements in fuel efficiency and emissions technology, though this often requires careful consideration during the swap. The increased reliability compared to older engines is another key motivator.
What's Involved in a 6.7 Cummins 2nd Gen Swap?
This isn't a weekend project. A successful 6.7 Cummins swap requires meticulous planning, extensive mechanical knowledge, and a significant time commitment. Here's a breakdown of the major components and considerations:
Engine and Transmission:
- Engine Source: Finding a suitable donor vehicle (likely a later-model Ram) is crucial. Ensure the engine is in good condition and comes with all necessary accessories.
- Transmission Compatibility: The transmission is equally important. The 6.7 Cummins typically utilizes a 68RFE automatic transmission, which requires extensive modifications for compatibility with the 2nd-gen Ram's drivetrain. This often involves custom adapter plates, driveshafts, and potentially a modified transfer case.
- Wiring Harness: The 6.7's wiring harness is significantly different from the 5.9's. A custom harness or extensive rewiring will be necessary.
Mounting and Fabrication:
- Engine Mounts: The 6.7 Cummins is larger and heavier than the 5.9, requiring custom engine mounts to fit properly in the 2nd-gen Ram's engine bay. This often involves significant fabrication work.
- Exhaust System: A custom exhaust system will almost certainly be required to accommodate the larger engine and transmission.
- Cooling System: The 6.7 Cummins' cooling system demands are higher. Upgrading to a larger radiator and potentially an auxiliary transmission cooler is essential.
Fuel System and Electronics:
- Fuel Pump and Lines: The 6.7's high-pressure common rail fuel system necessitates modifications to the fuel tank, pump, and lines.
- Electronic Control Modules (ECMs): Integrating the 6.7's ECM with the existing vehicle's systems is a complex task often requiring custom programming or aftermarket solutions.
What are the Common Challenges of this Swap?
The 6.7 Cummins swap presents several significant hurdles:
- Complexity: The sheer complexity of the project demands substantial mechanical expertise. Improper installation can lead to serious issues.
- Cost: The cost of parts, labor, and potential unforeseen complications can be substantial.
- Fabrication: Significant custom fabrication is often required, necessitating welding and metalworking skills.
- Wiring: The complex wiring harness demands considerable electrical knowledge.
What are the Alternatives to a Full Swap?
For those seeking increased power without the immense undertaking of a full engine swap, consider these alternatives:
- Turbo Upgrade: Upgrading the turbocharger on your existing 5.9 Cummins offers a significant performance increase at a lower cost and complexity.
- Performance Tuning: Performance tuning can significantly improve the power output of your 5.9 Cummins.
Is it Worth it?
The decision of whether or not to perform a 6.7 Cummins swap ultimately depends on your mechanical skills, budget, and the desired outcome. If you're an experienced mechanic with the necessary resources and a desire for maximum power and reliability, it can be a rewarding project. However, for those lacking significant mechanical experience, the challenges are substantial. Weigh the pros and cons carefully before undertaking this demanding modification.
This guide serves as an overview. For detailed instructions and specific part requirements, it's crucial to consult specialized forums and resources dedicated to this specific swap. Remember, safety and proper execution are paramount.
