Hey guys so I got a really sweet deal on a 1990 f350 crew cab that has a cherry body and frame, not to mention it is 4x4. I only got it for 900 bucks. Even the tires have good tread on them LOL. So knowing that its at least well worth its cost in weight at the scrap yard and axles i sprung on the deal.

The bad part is it has a 351w and complimentary e4od in it. Also the dash wiring and smog has been royally *******ized. I got it running for under 100 bucks with pieces of harness and a stock instrument cluster i had laying around from another project. After i realized how ridiculous a 351w was in this 8000+ lb truck, I started dreaming of either a 7.3 idi or 12v cummins. The gas mileage and power are real crappy and I got it with the intention of using it for my tow rig for my ranger as it is a mud racing truck and I want to start going to other venues outside of the area for fun. But 9 miles to the gallon will kill the already high cost of racing, so i want something else a little stronger and more meant for towing.

So one of my fellow racers had mentioned to me he knew a man who had a 1995 f350 2wd with a powerstroke in it. apparently it had been a utilty bed or something and he took it off and extended it intending it to be a roll back truck. When he took it off the jackstands the thing snapped in half, so hes done dumping money into it I assume and is willing to sell it for real cheap. So this i feel is my calling.

I have read both Chicagodragon's and Midwest's write ups on theyre other than PSD swaps but i soon realized that there was one big difference between my endeavor and theirs. My truck is a brick nose so I am afraid I will be doing a lot more fabrication I don't want to do as I want this to be a factory reliable truck. Also the donor truck is a zf5 2wd and i know zf5 4wds are near impossible to find or require rendering an appendage to get.

So those being my issues, these are more or less the major questions I am having.
-Are the bodies close enough that I can swap the radiator support, dash and wiring to be able to support the PSD with out major modification (i just dont want to have to make a whole radiator support or dash harness out of scratch) And I would kind of like to keep the brick nose, but am not opposed to the newer front end.
-Anyone have any ideas that dont require me buying another transmission, as a 4x4 zf5 would prob cost about as much or more than how much I bought either truck for. (or a divorced transfer case for that matter, considering options on making the one i have divorced).

I have not even checked the condition of the proposed donor but I just want to get some details checked before i start on this.


PS: I hope this in the the right section but if needed I will post in the brick nose section.
Oh and I am not afraid of modification, i would just prefer it to the minimum as this will be a road tripping type vehicle and I just don't want to have a list of things Im thinking of while driving well out of the area with a trailer on.

Thanks,
Drew

 

Put the psd in it and swap the front clip.
The frames will be the same.

 

The E4Od that's in your truck will not bolt to a diesel. You need to replace the trans.

You could take the E4OD that's attached to the diesel and rebuild the trans with the 4x4 output shaft from your current trans. That would converter the 4x2 trans to a 4x4 trans.

 

X2 on Mikes idea. You will also have to change the whole dash and all of the wiring. The ZF5 can have the tail shaft changed to a 4x4 tail shaft.I don't know if the transfer case will work or not.

 

To convert a 2wd ZF to 4wd ZF, the trans has to be completely torn down and the output shaft replaced. I would do what Mike and Kevin said, change the whole front clip, change the dash and wiring, and find a 4x4 ZF. If your t-case is a 1356 it will work, but you will have to have both front and rear drive shafts made or find some from a 4x4 CC ZF truck.

 

I know i have to change dashes and all wiring, so those dashes will essentislly bolt in to my body style?.
I know ill need a 4x4 transmission. Theyre just expensive as all get out.

Im really tempted to try making a divorced 1356transfer case. Then i wont have to drop as much as the truck on the tranny.

Also my intent was to keep the brick nose. There is absolutely no rust on it. Can the bricknose be bolted to the PSD rad support?

 

The 95 OBS rad support will NOT bot into the 90 Brick nose, but I can be made to work if you are handy. Or just get a 460 Supercool radiator and be done

You will want to swap the 95 dash into your 90 and NO, it will NOT bolt in, you need to do some fabrication. You will also need to weld up some no longer used holes in the firewall and make some new ones., use the COMPLETE 95 harness(right to the taillights).

For the trans, just get a 4wd rear housing(about $130) and a 4wd output shaft(about 150) then use the 1356 t-case. You will need to shorten the front drive shaft and lengthen the rear one

 

If the 95 cab is in good condition then just swap the whole cab

 

It is NOT a crewcab like the 90 is

 

Ah I missed that part.

 

Screw that, too much work. Buy a crew cab for $10,000-12,000 that's minty and call it a day. You'll spend alot of time and money ont hat kinda swap.

 

Thanks Diesel Brad those are the answers i was lookin for. Im gonna check the truck out ptobably this week. Ill let you know how it is. Also where would you find that tailshaft and tailhousing. I also dont recall if those trannys require ford special tools to pull apart as ive only done one and that was a long time ago.

 

Um...if the zf truck was a cab n chassis...it has the shorter output doesn't it? It just needs the park brake pulled and adapter swapped?!?!

 

No, only if it is a F-superduty would it have the 4wd rear housing and short shaft

 

aww crap,i just reread that,yea,350..not f-super.yea...that project is not really practical.