Duramax-Swap Ford Nicknamed Tatonka

Lead Photo-sized Copyright_Mikes_Race_Photo

It’s a common point of view that a truck project is never really done, but few go under the knife as extensively as Joey Sotomayor’s yellow and black truck, called Tatonka. While the body is easily recognizable as a 2001 Ford Ranger, it looks somehow different at first glance. That’s when you notice the FiberwerX flared fenders and Super Duty grill that has been cut, narrowed, and reshaped to fit the Ranger’s front end. The custom grille is just a hint at the extensive work that has been done to hide what lies beneath, a Duramax swap.

Duramax swap

If the black stripes don’t grab your attention, the custom Raceline beadlock wheels that resemble hazmat symbols will.

Joey and his crew are regulars at the Azusa Canyon OHV area in Southern California. They love to challenge the terrain there, but they also make a point of coming to the rescue when others get stuck.

A Ford Super Duty grille and lights were modified to fit the Ford Ranger body, giving the truck a unique look. In addition, the 9.5/44-15 TSL Bogger tires mounted to Raceline 15x14 monster beadlock wheels get into and out of anything Joey chooses to negotiate. The tread design of the boggers can best be described as “gnarly.”

Tatonka is capable of getting out of almost anything on its own. For others that are less fortunate, there is a PTO-driven 30,000-pound winch with 300 feet of cable mounted between the frame rails out back. The number of people Joey has helped to get unstuck and the show he puts on in Tatonka have made him somewhat of a celebrity at the OHV area. His personal best had him doing 31 recoveries in a single day!

Duramax Swap

The ’87 Ford F350 frame and the 2001 Ranger bed that sits on it have been bobbed in the rear. The pintle hitch, huge hook, and fairlead for the 30,000-pound PTO winch signal that Tatonka is set up to do heavy-duty recovery work.

Joey puts his truck to the test all of the time, so every inch of it has been built with strength in mind. The chassis started life under a 1987 F-350 and has since been gusseted, boxed, and bobbed in the rear; also, several crossmembers have been added.

Careful planning has been used in the design so that the in-cab cage is mated to the frame in the same location as several of the added crossmembers. This ties the entire truck together and provides the strength needed when counting on the torque from the Duramax swap or the grunt from the winch.

Transfer case braces run forward and aft, tying into the frame’s ample crossmembers (left). The roll cage ties into the frame at the same point as the transfer case crossmember. Much thought in the design stage has resulted in a structurally sound chassis that holds up to abuse (right).

The drivetrain is pure beef. Joey has had several big-block Fords under the hood in naturally aspirated, fuel-injected, and propane-injected configurations. The big block is gone, and in its place is a Chevy/Isuzu Duramax LBZ diesel V8. The Duramax swap puts out 515 horsepower when programmed at the factory settings; 785 when cranked up to full race mode.

It has enhanced fuel flow and better breathing due to products from Pacific Performance Engineering (PPE). PPE also supplied the tuner that allows the enhanced programming to take place.

Duramax swap

PPE Xcelerator hand-held programmer allows precise tuning of engine and transmission parameters.

Plumbing on the – including the turbo, radiator lines, transmission plumbing, and brake lines – were all done by co-pilot and chief mechanic Andy Batestelli. The torque is transferred through an Allison six-speed transmission to a divorced NP205 gear driven transfer case with a power take-off that spins the winch.

Surrounded by an engine cage, the turbocharged and intercooled Duramax LBZ diesel V8 puts out 515 horsepower at factory settings; 785 horsepower when cranked up to full race mode. The front end structure is fabricated from .120 wall steel tubing skinned with a Ford Super duty grille and FiberwerX fiberglass fenders.

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The custom driveshaft built by Knoll Racing runs from the power take off (PTO) on the NP205 transfer case to a 30,000-pound winch with 300 feet of cable. Truly, Tatonka was built to go anywhere and recover stuck vehicles.

The front differential is a kingpin Dana 60 with 4:88:1 gears and a power lock electronic locker modified by Joey’s friend, Karl Knoll. Karl also helped with the custom high steer setup that handles the load when turning the 19.5/44R15 TSL Bogger tires mounted to Raceline 15×14 monster beadlock wheels.

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Karl Knoll built the driveshafts, axle assemblies, and high steer setup on the truck. All were designed with ultimate strength in mind.

Out back resides more of Karl’s work – a full floating 14-bolt with disc brakes and an Eaton Detroit Locker. Custom Atlas leaf springs designed by Fernando Gutierrez give a controlled ride while allowing ample articulation, and Rancho RS9000 shocks take care of the damping.

Duramax swap

The Knoll Racing 14-bolt axle in the rear has 4.88:1 gears, a Detroit Locker, and disc brakes. It is suspended by Atlas progressive leaf packs and dampened by Rancho adjustable RS9000 shocks.

The custom features continue when you enter the cab. Occupants ride in the comfort of PRP suspension seats that are securely mounted to the roll cage and are further secured by Mastercraft five-point harnesses.

A fiberglass FiberwerX dash was narrowed before being stuffed with Autometer gauges and a cheetah shifter for the Allison six-speed transmission. Diamond plate door panels protect the inner door workings (top left). The truck's control panel is mounted up high and dry and within easy reach of the driver (lower left). The Mastercraft five-point harnesses and PRP suspension seats are mounted securely to the in-cab roll cage assembly for maximum occupant safety (lower right).

A full complement of Autometer gauges are strategically placed in the FiberwerX dash that has been narrowed to fit the cab. A Painless Performance Products roll cage mounted switch panel overhead also contains vital fuses in easy reach while strapped in.

Whoever takes this wheel in their hands is in control of a very powerful beast of a truck. Within easy reach is a Grant steering wheel and Cheetah shifter. Brice Billets is responsible for the custom wiring, which includes a hinged, drop-down panel that makes access quick and easy.

The electrical panel (left) by Brice Billets swings down from under the dash for easy access. The custom slide-out drawers behind the driver’s seat keep tools and supplies safely contained during even the rowdiest four wheeling sessions (right).

Just behind the driver’s seat is a storage box with slide-out doors made by Joey who is a cabinet maker by trade. The box used to be mounted in the bed but was moved inside the cab.

Inside and out, Tatonka has seen non-stop evolution over the years. The many hours spent playing in the mud and rocks, not to mention countless recoveries have led to a prime example of the ultimate Duramax swap in an off-road vehicle.

Duramax swap

Azusa Canyon was mostly dry during our photo shoot. No matter if it’s bone dry dirt or deep gumbo mud, Tatonka goes anywhere with ample traction and power.

About the author

Mike Ingalsbee

For more than two decades, Mike Ingalsbee has worked as an automotive writer and photographer and covered just about everything that burns fuel or throws dirt. His writing and photography has been published in over 20 magazine titles and websites in North America, Europe and Australia. He has worked as a design engineer for several manufacturers in the automotive aftermarket and is a founding member of the Association of Motorsports Media Professionals, (AMMP), an organization that consults with racing sanctioning bodies on safety and media issues.
Read My Articles

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