2005 Ford F-250 Super Duty: Diesel Perfection

Garth Shortridge built this '05 Ford F-250 the way he wanted it-and did the majority of the work right in his own driveway. This undertaking was very inspirational to us here at Diesel Power, because although Garth had never tried any automotive project this extensive before, he took on the Cummins swap with no fear. Garth is a manager at a distribution center called GTM in El Cajon, California, and takes care of its diesel fleet, but he is not a professional mechanic.

Garth wasn't happy with his original 6.0L Power Stroke, so he sold the engine for $5,000 (with 15,000 miles) and bought an '06 5.9L Cummins (with 10,000 miles) for $6,000 to replace it. The technical support and parts (motor mounts, electronics, flexplate, and adapter plates) needed to complete the swap came from Destroked. Originally, Garth's Cummins-swap plan called for retaining the truck's original 5R110 five-speed automatic transmission. But Garth decided that if he was going to put the most proven name in diesel engines in his truck-he should do the same with the transmission. So with help from Destroked, he sourced a Cummins-to-Allison adapter and flexplate so he could bolt in an Allison 1000.

1101Dp 2005 Ford F250 Super Duty Diesel Perfection Engine Bay

The 5.9L Cummins engine was swapped in place of the 6.0L Power Stroke, but not before it received a fire-ringed head and ARP head studs. A K&N air filter, Spearco intercooler, and water-injection system support the compound turbos. For fueling, Dynomite Diesel 50hp injectors are supplied by an Industrial Injection modified CP3 pump and FASS 150-gph lift pump. The electrically powered vacuum pump was flipped to gain more room for the wiring and turbo plumbing. Garth plans on relocating the self-contained system to the frame of the Ford.

The 5.9L Cummins engine was swapped in place of the 6.0L Power Stroke, but not before it r

Built To Play In The Sand
Garth takes this truck off-roading in the sand dunes of Glamis near El Centro, California, so many things have been done to make the Super Duty perform better. For example, the batteries were moved out of the engine bay and attached to the frame to distribute the weight better. Another thing taken from the trials of Baja racing is heavy-duty nylon sheathing, which protects the hoses and electrical wires.

When we took a ride in this truck, we were convinced Garth did the right thing. The gauges, air conditioning, and everything else functions just like it did before. The only thing that didn't work was the cruise control, but he told us he never uses that anyway. The combination Garth put together utilizes the best parts from each manufacturer. He now has the durability and power of the Cummins engine, the strength and quality found in Ford's body and chassis, and the intelligence and strength of the Allison transmission-all in one perfect truck.

With the increased fueling, Garth decided he needed cooler EGT than his single turbo could deliver while hauling heavy loads up long grades. He put together a compound-turbo system in its place with a Turbonetics T-Series HP61 ball bearing over a BorgWarner S475 mounted to an ATS exhaust manifold.
With the increased fueling, Garth decided he needed cooler EGT than his single turbo could
There are three other Optima batteries located in the rear between the receiver hitch. They were put there for better weight distribution, but since they were so far back Garth needed to add a fourth battery closer to the starter.
There are three other Optima batteries located in the rear between the receiver hitch. The

Garth told us he modified the drag link to get rid of the death wobble coming from his solid Dana 60 front axle. The passenger side of the link was relocated to a higher position and received a Heim joint instead of a ball joint. The differentials have 4.30 gears (2,000 rpm at 65 mph) and Detroit Lockers.
Garth told us he modified the drag link to get rid of the death wobble coming from his sol
Destroked provided the Cummins-diesel-engine-to-Allison-1000-transmission adapter and flexplate. The front driveshaft was extended, and the rear one was shortened. The Ford crossmember's boltholes were elongated to fit with the Allison's transmission mount.
Destroked provided the Cummins-diesel-engine-to-Allison-1000-transmission adapter and flex
The Allison transmission control module (TCM) and Destroked XFC module were bolted to the driver-side firewall without drilling any new holes.
The Allison transmission control module (TCM) and Destroked XFC module were bolted to the

The exhaust is fitted with V-band clamps for easy removal. The NP271 transfer case was fitted with an Allison input shaft and Destroked adapter. The factory shift linkage controlling the transfer case's range selection was lengthened.
The exhaust is fitted with V-band clamps for easy removal. The NP271 transfer case was fit
The FX4 package provides an excellent interior, which makes cruising enjoyable. The transmission temperature gauge was mounted in the removable panel to the right of the steering wheel.
The FX4 package provides an excellent interior, which makes cruising enjoyable. The transm
Donahoe Racing Plush Ride leaf springs and Fabtech traction bars smooth out the rear suspension.
Donahoe Racing Plush Ride leaf springs and Fabtech traction bars smooth out the rear suspe

Pro Comp rims (18x9) and 37x12.50R18 BFGoodrich Mud-Terrain TA KM2 tires work especially well off-road. A Fabtech 6-inch lift and Bilstein shocks provide the right stance and more suspension travel.
Pro Comp rims (18x9) and 37x12.50R18 BFGoodrich Mud-Terrain TA KM2 tires work especially