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I have been thinking about the same idea down the road. I have looked around and asked questions everyone recommends the 4bt as it an easy fit. Myself I rather go with the bigger and stonger with the 6bt, after doing measurements it very small room for error as the engine bay is small an only about roughly a half inch of extra room. I know that farmboy productions did the swap on 97-03 style, the truck can be seen on youtube its forest green
well, like you said going all out. I was also planning of replacing the tranny with an Allison transmission if I went with the 6bt. It's a blueprint i have that wont get done for a long time ha
A 12v weights in at 975lbs and a 24v weighs 1,150lbs. The 4BT weights 782. Adjustments will have to be made to the front end of the 1/2 ton truck to hold a 6BT and maybe even the 4BT. The weight of these motors will be the issue. Your front suspension wont last very long witht that kind of weight. Remember that the 4BT weights around double of what your 4.6L would weigh.
The 4BT would be less powerful than your original 4.6L as far as stock hp and torque goes.
I would love to see your numbers that back that up. HP yes i would agree, but that diesel would put out more ft-lbs any day. I could be wrong, but for towing I think the 4bt would be far superior to the 4.6l.