Excursion 12v/nv4500

[Gots_a_sol]

Tach works. I tried it first without knocking off the extra tooth and notta. Cut it off and boom, worked great.

Home made tone wheel and the stock crank sensor.




Also got a belt on there. It was a little short, but I had a smaller alternator pulley which just barely got it to fit. It is a special pulley in that is has a v-belt drive in addition to the serp belt so I'll pick up a normal pulley to replace it since I won't be able to use the v-belt drive with the alt in this location.

[Gots_a_sol]

Another one for the ugh category. The stock coolant expansion tank/degas bottle/whatever the fkcu you want to call it won't fit anymore thanks to the a/c compressor.

Picked up this little Moroso tank, just enough room. It has a port on the bottom and on the left side for tying it in. Plus it looks nicer than the yellowed out plastic tank. With this tank it will work like a standard system with a normal radiator cap and a small overflow bottle.




Also played with the exhaust a bit. Ordered a kit for a 7.3 excursion, will use everything but the down pipe. Looks like my mocked up downpipe is about 10" too short of connecting with the rest of the system.

[ellis93]

It's a Degass tank.....stupid crap. I like the aluminum tank as well....it definitely adds class to the engine compartment. It's all looking good man!

[Gots_a_sol]

All gauges working as they should.





Alternator overdrive pulley compared to stock

[PToombs]

Why did you overdrive it?

[dazedandconfused]

Why did you overdrive it?

I was wondering the same thing

[Gots_a_sol]

So the belt I bought would fit



(thats actually true)

The cummins doesn't spin up as high of rpm as the v10 did, so I can spin the alt a bit faster and have it make full power at a lower rpm.

The excursion has A LOT of electrical crap in it and the stock size alternator is barely sufficient (130a IIRC). Fun fact, an alternator from an ~04 crown vic with the police interceptor package bolts in place of the v10 alt and is 200a. One day I'll pony up for one. I'll also eventually build a dual battery tray.

[thrashingcows]

Damn that is looking sweet! What model of Volvo runs the Taurus/T-bird style motor on the electric fan? Inquiring minds want to know....

That tone wheel looks friggin dangerous! Should be on a table saw somewhere hacking up lengths of lumber....

[Gots_a_sol]

Damn that is looking sweet! What model of Volvo runs the Taurus/T-bird style motor on the electric fan? Inquiring minds want to know....

That tone wheel looks friggin dangerous! Should be on a table saw somewhere hacking up lengths of lumber....

Mid-late 90's volvos in various models. I think a new dorman replacement is about $125 if you can't find a used one. Also I've read they changed the blade profile in like '96 and the newer style moves more air. The taurus fan has larger diameter blades and moves even more air yet, but the mounting flange on the volvo one makes mounting it 100 times easier.


And yes, no sticking hands down by the front of the engine while its running. Shouldn't do be doing that anyway, but now there is more incentive not to



No pics, but I got my downpipe welded up and the exhaust is installed, just need to trim the tail pipe a bit and probably hit it with some black paint.

Pro tip, use these clamps instead of the cheap u-clamps that come with the exhaust kits. Sooooooo much easier to deal with/make adjustments/take apart later.

[CumminsPower59]

Pro tip, use these clamps instead of the cheap u-clamps that come with the exhaust kits. Sooooooo much easier to deal with/make adjustments/take apart later.

I've been using that style for years. Works great

[ellis93]

I thought that is what the diamond eye kits came with?

[PToombs]

So the belt I bought would fit

I guess that's one way to do it! I would have taken the belt back and got a longer one.

[Gots_a_sol]

Took first test drive with it today. Got about 5 miles from home and ran out of fuel This is the first time I've ever run this engine out of fuel and it wasn't a pleasant experience to get it going again.


But after fussing with it for a while she coughed back to life and ran great.

Couple notes:
Need to relearn driving a manual trans diesel again. May have smoked out an intersection (I really, really don't like doing that)
Need to knock out the restricter in the fuel neck so the diesel pump handle will fit
Clutch pedal sucks. It is basically on the floor and 60% of its travel is just free play/mushy.
Need to tighten up the gap on the tach sensor as it is a bit jumpy.
Need a proper overflow bottle, I just stole one off of one of my bikes.
Trans rebuild was a success. It wasn't really bad before except 3rd gear would grind unless you very gently shifted in to it. For the few miles I put on it, no more grinds.
Don't do test drives in the dark

[thrashingcows]

Wow...that is some quick work you did on the conversion...I am very impressed, and a bit envious too.

[Gots_a_sol]

Boring reading ahead, just ignore if you don't plan on ever putting a cummins in an Ex or Super duty



So the a/c works through the computer. And apparently the computer is fussy about what inputs it gets before it will send a signal to the a/c clutch relay. Solution is to bypass it with another relay.

This info is for a 2000 Ex with a v10. Other years/engine types may vary.

The original relay is in the power distribution box #302. Pin 86 is grounded by the computer to activate the a/c clutch.

To make it work, you pick up the wire coming from the high pressure switch to the computer. It is Tan/Lt. Green and goes to pin 41 at the pcm. You can either grab it at the switch or at the pcm, I chose the pcm since you're working in that area anyway. This wire has +12 volts on it when you select a/c and when the high/low pressure switches are in their correct positions. You will connect this wire to pin 85 on the new relay.

The wire that goes to pin 86 on the original relay is Pink/Yellow (may be red/yellow). I don't know what pin it is at the pcm, I just picked it up in the fuse box. You will connect this wire to pin 87 on the new relay.

Pins 30 and 86 are grounded on the new relay.

The idea is that when you turn on the a/c, you end up with +12 volts going to the pcm (now new relay). You need ground to trigger the a/c clutch relay, so the new relay is just flipping the 12 volt signal to a ground signal.

Recap:
Tan/Lt. Green = pin 85
Pink/Yellow = pin 87
Pins 30 and 86 are grounded.

I can draw a picture if someone needs it.