lets turn this into the OFFICIAL Powerstroke Swap thread, so we can refer people to this, so we dont have little bits and pieces here and there in different threads since this question has been asked alot lately. Chime in any info you have.
My DD is a 1996 F350 PSD (Powestroke Diesel).
You will definately need a donor truck. Powerstroke 7.3s started mid way through the 1994 model year. 1994 also offered the 7.3.L IDI, and 7.3L Turbo IDI. Here is a link to a site, about 3/4 way down the page it starts describing how the PSD injection system works, read this to fully understand what you will need for your fuel system. http://pages.prodigy.net/stevebaz/_i...az/index3.html
anytime there was a comparison, it was between my 1990 bronco(m5rod), 1990 f150(m5rod), and 1996 f350 PSD(zf5).
To do the swap you MAY be able to use your stock engine x-member, with some fabbing. The PSD engine mounts sit flush atop the face of the X-member. The BKO x-member has a large hole on the drivers side for clearance of the 302/351w oil filter. You may or may not be able to get the PSD perch over this hole, to attatch the mount to. If not youll need the PSD engine x-member. The pass sides are exactly the same between all my vehicles.
The PSD rad is huge, the radiator core support is different than a gas rig. If you buy a PSD donor truck it will have the 92-96/7 front end. If you have an older style, upgrade the whole front clip so you can use the proper rad support for the large diesel rad.
The automatic version was the E4OD, diesel rated version. The manual is a zf-5 5speed, diesel rated version as well. My PSD is a zf5, the tranny x-member is different, on the drivers side it drops lower down for clearance of the D-shaft, and attatches to the outter face of the frame. The t-case is a BW 1345
all the info for suspension fabbing can be found in the SAS forum.
The 7.3L PSD engine weighs in excess of 1000lbs. You need some springs for under a diesel engine plain and simple. You have 2 options, both require an extent of fabrication. Either way, putting a solid axle up front will be the best bet, and since youre going solid axle go right for the D60. Options:
1) Leaf springs, the bronco never came with them, youll need to need to fab up the hanger mounts on the frame for the leaf pack to attatch.
2) Coil sprung, the D60 never came coil sprung, youll need to fab up the bottom coil buckets
the f250 TTB doesnt work in a 1/2 ton chassis truck, therefore would need fabbing to work, and any fabrication should be spent to do the job right, with a dana60 straight axle. Technically speaking, you 'could' use the stock bronco TTB with some 2wd f250/f350 PSD coils, IF
you like chewing through tires and breaking axles, and crown/pinions everytime you put it in 4wd. As I said the PSD is not only more power, but twice as heavy.
-For the rear-
an 8.8 or 9" wont cut it, youll need a sterling 10.25/10.5 or Dana 60/70
IDFK! read the link and reasearch anything left unclear via the intraweb! Or try the 94.5-97 Powerstroke section on Ford-trucks.com
I hit writers block, thats all for now.