I have a 2004 F250 2WD and want to convert it over to 4WD. Anyone ever take this on...successfully?? I have a Dana 60 front axle, tranny and xfer case. (have already heard "buy a new truck")

 

not a big deal u just need drive shafts and transfer case shaft. also the hump is different for manual and auto transmissions. your also gonna need the springs and springs mounts and all that stuff.

 

I wondered the same thing when I had a 2wd and everything I heard was "its just easier to buy a new truck" BUT if you have everything seems like you just need to be a good fabricator

 

u don't have to be a good fabricator .the frames are the same. everything bolts on. you just need everything from a 4x4 truck.

 

No offense, but what exactly is your question? According to you everthing is bolt on and you know everything you need, so what do you need to know from anybody here?

 

I think he was commenting on the OPs question, not asking one.

 

i agree everything is just bolt in,they do not make manual bodies different from auto bodies,i dont know how many auto to manual conversions i have made in mustangs....you just need to research what additional parts make a 4wd,and get those and add them,hell my 2wd even still have all the places to put the 4wd controls.
my suggestion,just look at what you don't have that a 4wd has and add them.
i love projects like this!!! and mine always come out good as factory.
just don't forget to bring allot of drive and determination.
good luck,it can be done!

 

Having all the parts is the trick, it seems. The transmission is important, because the tail shafts are different. Hopefully you have a manual shift transfer case, that will make things a LOT easier. The hole is even already in the floor for the shift lever.

You might have to have the rear drive shaft modified, unless you got one of those too (from the same wheel base truck as yours, etc). The transfer case moves the start of the drive shaft back so it needs to be shorter.

You'll need leaf springs, I think. And spring hangers, and probably new u-bolts. You might need brake stuff unless they're already on the axle.

There are a lot of parts to think about but if you can get them all together, it shouldn't be a monumental task.

 

P.S. You'll need a track bar. And all of the steering linkages, up to the steering gear box. I think the steering gear box is the same, though.

 

I've seen lots of E-350's converted and the guys told me it really wasn't that hard, ^so I'm going to think the pickup has got to be easy if you have factory parts! It sounds like fun!
Jim & fat Monty

 

thanks for all of the replies. does anyone know if the transfer case has electronic controls that need to be programmed into either the body controller or engine ecu? If so, Id guess its not a big deal to either reprogram or swap out box's. Thoughts??

 

Hopefully you got a manual shift transfer case. If you got an electronic shift, it's way, way, way, way more complicated. What module needs to be there depends on what year the truck is. You'll need wiring harnesses, relay boxes, relays. It's not something I would want to even consider.

 

David is correct! The ESOF is ^so overly complex, I would go with an manual shift X-f'er case as well then you never have to guess is this the right year relay box schematic! Is my GEM going to need to be reprogramed?ect...ect..!
Jim & fat Monty

 

Yeahhh. Must of been cross-eyed when I hit that reply button.

 

Yeahhh. Must have been cross-eyed when I hit that reply button.