I decided it was time to transfer my old post from the old BSN to here 
Unfortunately, I can't edit posts on the old BSN, so it's going to take a little longer to add in all the links and fix any broken formatting issues. But without further ado, here it is:
Changing Companion Outfits
You will Need:
Modio
GFF Editor
Dragon Age Checksum Fix
Appearance #’s (URL)
Armor ID’s (URL) and (URL)
A flashdrive (to save the game onto)
1. Assign everyone a number. This will make sense later:
Isabela 1
Anders 2
Merrill 3
Sebastian 4
Aveline 5
Fenris 6
Bethany/Carver 7
2. Start DA2 and figure out which save you want to transfer onto your flashdrive. DA2 assigns a four number ID for each save, so memorize that. Don’t memorize an auto-save. You can’t mod those. Alternatively, you can just start a new game with your flashdrive already in the xbox (you will have to format the flashdrive first, of course). Go to settings and transfer the save from your harddrive to your flashdrive.
3. Pull your save up on Modio. Open Modio and select “Open from a Device.” Make sure you open the right save. It should end in “u.” A save ending in “a” is an auto-save, and those won’t work.
Once the save is open, click on “File Contents” tab. Open “Saves.” “Extract File” for savegame.das and savegame.das.x. The default should be your desktop.
4. Open GFF Editor. The first thing you want to do is make everyone naked (lol). This is so their new clothes will “stick.” You can find the codes for naked humans, (male) dwarves, and elves in the above link, “Appearance #’s.” It’s just 15 for human males, 16 for human females, 12020 for male elves, and 12021 for female elves. Alternatively, you can just input another character’s default body; for example, Aveline’s default start armor is 1010; you could give that to Isabela … but keep in mind you’d now have a dark-skinned Isabela head on a very pale body.
Where you do this in GFF Editor:
SAVEGAME_PARTYLIST > SAVEGAME_PARTYPOOLMEMBERS > (select desired party member)
SAVEGAME_APPEARANCE > SAVEGAME_APPEARANCE_TYPE.
Go ahead and change it for SAVEGAME_APPEARANCE_ORIGINAL_TYPE, too. Make sure you are hitting "save" after each of these changes. Note that you can’t just, say, give Fenris a female human body just for sh!ts and giggles; the game won’t read this anomaly and Fenris will just be a floating head when you start the game up again.
5. Now that everyone’s good and naked, go back to Hawke:
SAVEGAME_PLAYERCHAR > SAVEGAME_PLAYERCHAR_ CHAR > SAVEGAME_EQUIPMENT_ITEMS.
Here you’ll see a list of everything Hawke has equipped. His/her weapons are first, followed by armor and accessories (rings, etc.). Find the desired equipment. For example: gen_im_arm_cht_med_act3_02. That’s a medium chest piece, the one you get off the high dragon. Copy it. (Ctrl-C)
Now go back to your desired Companion. Let’s say Isabela. Expand her. Go to SAVEGAME_EQUIPMENT_ITEMS. Find her chest piece. I apologize; I can’t recall exactly what their default chest pieces are called, but it has the letters “flw”and the companion’s name (i.e. Isabela) in it. Should be pretty easy to find.
Delete it. Highlight SAVEGAME_EQUIPMENT_ITEMS. Paste. Now this is important: Go down to the newly pasted in chest piece (it should be the last number) and expand it. Go to OBJECT_ID. Remember the number you assigned everyone? Add that character’s number. So, “1” to Isabela. Just add a one to that long number there. Click “save.” The reason you do this is because you just gave Isabela an outfit that only Hawke is supposed to be wearing. So the game is going to go “huh?” if you don’t change that object ID. That tells the game that this is a totally new outfit, wink wink.
If this is Isabela, Anders, Bethany, Carver, or Aveline, you can stop here. When you start the game, they will be wearing the same outfit Hawke is currently wearing. If it is Fenris or Merrill you will probably HAVE to change it because they are elves and cannot wear (most) human armors. You can, of course, also choose to change the human companion’s outfits. What we did here is basically just carried over all the stats.
SO! Pulls up the Armor ID’s you downloaded from the list at the top of the page here. They are divided into Light, Medium, and Heavy armors. For Merrill and Fenris, there are only a few outfits available. All of the mage robes and the commoner outfits should fit them. But check out the Read Me file I uploaded; it has additional elfy outfits, including various Dalish armor and Athenril’s armor. Good stuff. There’s also dwarven armor if you want to switch out Varric’s default armor.
Always hit “save” after each one of these saves you made. If something weird happens when you start your game up (floating head, etc.) or something didn’t take, it’s probably because you forgot to save or maybe pasted in an extra space at the end of the Armor ID.
6. “Save as” on GFF Editor.
7. “Resign” using Dragon Age Checksum Fix.
8. Back at Modio, replace savegame.das and savegame.das.x with the saved ones on your desktop. Rehash and Resign. Save to device.
Load up your game, and voila! Hawke’s companions are now wearing different outfits and armors.
*** Note that they may now be bare-handed and bare-footed. To give each companion gloves and boots, simply repeat the process, whereby you copy/paste Hawke’s gloves into Isabela’s items, etc. Some outfits, like the mage robes, do not require gloves and boots.
*** Note that you can also change the appearance of both Hawke’s and companions’ weapons. The process is exactly the same; simply replace the Armor ID with the weapon you want to appear. Swords, shields, daggers, staves, and bows should all be available from the link above. You can, for example, replace mage Hawke's staff with a two-handed sword. Hawke will still have access to his/her spells, but the animation will simply consist of Hawke swinging his/her sword (with the bad guys turning into ice from Cone of Cold or what have you). Alternatively, you can take rogue Hawke's or Isabela's two daggers, copy them to, say, Fenris, and suddenly Fenris will fight as a rogue with two daggers.
*** Note that if you romance a companion, s/he will switch into his/her default outfit after the romance takes place. You’ll have to change them out all over again. Additionally, Aveline sometimes will resist outfit changes all throughout Act 1.
HEAD MORPHS
You can change a companion’s actual appearance (head morph), too. In other words, you can give Isabela Bethany’s head and Anders Cullen’s head. I find this particularly refreshing when I’m on my one millionth playthrough; it’s like meeting entirely different companions.
How:
1. In GFF Editor, go to SAVEGAME_PARTYLIST > SAVEGAME_PARTYPOOLMEMBERS > (select companion, i.e. Isabela) > SAVEGAME_APPEARANCE > SAVEGAME_APPEARANCE_MORPH_NAME.
2. You’ll see “hf_isabela” here, which stands for “human female Isabela” (duh). You can change out Isabela’s name here for virtually any other Dragon Age 2 character, major or minor. Note that if you give her a female elf’s face (e.g. Athenril) you will have to change her body to female elf, too. I recently gave her Grace’s face (the mage woman with the tattoo on her face from “Act of Mercy”) and it looked really great. I gave Aveline Macha’s face (Macha, the templar recruit Keran’s sister). I’ll provide a list of character names I know work:
UPDATE: This link HERE provides the head morphs of all the characters in the game!! Just scroll down to the first spoiler and open it. ENJOY!
3. As always, hit “Save” after making this change.
*** Note: You can’t use Tallis’ head or body for any of this because it’s all one construction. You can, however, change Tallis’ head morph and outfit/armor. Just keep in mind that before and after that party she will default back into her original outfit/face.
Good luck! 
If you have questions, thoughts, or corrections, please PM me. Please note that I am a modding newbie and put this together for other newbies. I am happy to help others and equally happy to accept corrections.
UPDATE: You may notice that when you copy Hawke's armor and paste it to a companion's, and then change the companion's armor ID, that the color may be different. This is because all of the stat info transferred over along with the armor. So even though you changed the armor ID (the armor's "shell" appearance), all of the stats are the same. This includes material type, which determines the armor's color. You can expand the info for that armor piece and find the material type, then change it to your desired color. Here's a wonderful list, courtesy of BSN user Sevec:
2000 Red Steel
2001 Onyx
2002 Silverite
2100 Crimson
2102 Argent
2103 Gilt
2200 Scarlet Dyed
2201 Charcoal Washed
2202 Silver Threaded
2203 Gold Threaded
Sevec adds, "The Gilt looks great on the Jedi Robe, sort of Dark Red and Brown. The onyx is a fantastic dark gray that really brings out the darker side in Merrill, not to mention the emo side in Fenris. Now I need to try the Onyx on other outfits." Wow, cool! Thanks, Sevec!
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