2011 F150 /BMW Diesel Swap

[Lost0187]

The F150 M57 swapped 6R80 build is basically done its running, driving, and shifting. On top of that even got the air models torque models to be realistic and in line with actual M57 power output. Doing a few more things with the converter but the stock converter may need to be upgraded to suite the diesel application to its best ability. I'm pretty happy with this one I ca say most guys wouldn't even wat to attempt to try something like this but anything is possible with time and determination. When The project is done I hope the customer post some cool videos of his build cause I think this is the first of its kind and i had a privilege of getting the transmission side figured out. #YAKPERFORMANCE

[Lost0187]

I'm happy to Report to the community the stand alone Control of a 6R80 is possible if you are trying to mix the transmission with other engine applications other than Ford. This one has a 3.0L 1998-2010 straight 6 Diesel with a custom bracket to adapt the eco boost 6R bellhousing. Very cool build done by a gentleman in Canada, F150 has been driving for over a month now. Originally the gear box was manual but he had a great idea to adapt the 6R80 and due to the M57 using a similar ZF6 which the 6R80 is based off it worked beautifully.

Here is a log I got over the weekend given this combo and the fact we are using a 2011 TC-1797 I cant be more pleased with the results. It took some time to get the torque modeling close to actual so the gear box could engage the proper pressures per the driving condition. As well as making the torque converter react the way we wanted it to given its not perfect for the diesel application but its doing its job well. From here I'm gonna take a big win on this one and go to another strange combo to see what else I can do with the VCM software.

[Lost0187]

So we have made a lot of progress with modifying the calibration to better suite theM57 BMW 3.0L DSL engine the transmission shift points are better suited to the application and the torque model is now showing minimum IPC error to make the actual torque model from the motor inline with what is set in the calibration. This helps the shifts and the torque based shift models for the tcc and pressures more accurate and eliminate any flair shifts or harsh TCC engagements. Hoping to have the final calibration done by this week so the customer can start showcasing the truck and what it is capable of.

The ECU he is using is a 2010 model BMW manual controller linked with the Eco boost tricore PCM boost and map are actual from the motor and as well as the temp sensors ad other inputs we incorporated to help the Ecoboost PCM have the data it needs for proper 6R80 operation.

Here is the latest logs been working back and forth trying to get everything where it needs to be. Truck has now been in use a few month and all has been good other than the fine tuning of the torque modeling ad turbo model.

[Lost0187]

I have been hard at work making the BMW 3.0 DSL 6R swap function as close to a stock truck as it can be the torque model i have come up with is inline with a real world torque model you would expect from a modified 3.0 M57 engine. I like to make the shifts nice and smooth at cruise but have a nice crisp gear change at higher pedal input. This also depends on what the user desires as far as his or her preference. This F150 has now been driven going on 3 months with no mechanical issues which is always a great thing especially when you are venturing into things that are new and have not been done before. But the ECO BOOST TC-1797 has been doing it job of controlling the 6R as well as giving us live engine data from the BMW M57 engine like actual boost, rpm, map and other miscellaneous temperature outputs.

Anyone interested in doing a transmission swap 6R, Allison, 6L with a engine that it ever was intended to run with im sure I can help make it a reality.

[Lost0187]

Figured I post this the truck has now been driving numerous months and all is good transmission seems to holding up great to the M57 engine swap. From a calibrators perspective this took a lot of time to get right and I hope to do other similar vehicles combos in the future. The 6R transmission is very stout for a gas 6 speed auto and ford did a awesome job with its design though the earlier models has some issues.

The hardest part was getting the "non existent" engine calibration close to the actual M57 output torque and load and diesel is so different vs most gas calibrations. Diesel is more qty based and injection timing vs air coming in spark and fuel going in. But a lot of hard work pays off its working, shifting, and making torque based calculations like a normal engine would. Most guys would not want to touch something like this and might say it couldn't work but it did and very happy I could come through and make something that operates as if it came that way.

Check Out This LOG

[Lost0187]

If you are interested in doing the project i a 2015 GM 1500 you can message me directly and I can walk you through what all is involved in making this work for your application.

[4RubbersAday]

I have a 2008 f250 with a blown 6.4. I hotshot with it with an aluminum trailer and light loads under $7k. Would it be possible to convert it to an m57 with the speed of air pistons? They claim big improvements with the golfball pistons and I think the engine and tuning could put me at low 20s mpg towing light. Might try a 5.9 swap but I think the m57 could be an efficient swap

[Lost0187]

So you could go to the M57 but a F250 is a very large truck you might truly be better off with a Cummins common rail swap. If you go with the cummings we can absolutely put a Allison behind it and 6 gears. The M57 could also work but the transmission might be to small if you go for a 6R80 now if you can adapt the 6R140 that would help. But again the M57 is more deigned for a lighter vehicle like 3 series and X5 series BMW vehicles slapping one in a F250 might be counter productive. Now a 1500 series Ram, GM, or Ford it could power nice but on heavy duty trucks I just feel there are better options out there.

[Lost0187]

Here are some recent logs from the 2011 F150 with the M57 truck has been good and seeing a lot of driving customer maybe swapping out to a tighter converter in the coming weeks which will help light driving habits. The Eco boost converter I believe is just a little loose with the TQ production of the M57 DSL engine. We might go to a 6.2 or 5.4 converter which have a lower stall. We have a slight shudder which we worked out in some other test we ran but we think also the converter is on its way out.

He pulled the original used trans we started with and tore it down and was surprised there wasn't damage just a few hot spots on a few clutch packs. We didn't know if this was prior to the install or from our early test back in December 2023.

The biggest obstacle when doing something like this swap is you now have no control over the engine for TQ management so you have to tune the engine side of the calibration to mirror what the engine is doing and then the transmission can use that data to complete shifts properly and accurately depending on pedal position and TQ demand from driver.