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1991 F-150 4X2 to 4X4 conversion

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Old 08-19-2014, 06:09 PM
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1991 F-150 4X2 to 4X4 conversion

Hi all, I have been lurking here a long time, tons of great info!

I read Minnesotafisherman's thread about his conversion in great detail and will most likely use that as the foundation for my conversion as well. One thing I haven't been able to locate via various searches both on this site and google, is an interchange list. I am going to hit a junkyard this weekend to see what is available.

I basically just need to know what years are transplantable into my 1991. Is it 87-96 or is there a wider range that I can look for? I have the E4OD now and assume I should grab the E4OD out of the donor truck (because of the ECM) along with the transfer case, cross-member, 4x4 shift linkage etc. I would really appreciate any info anyone can pass along! Thanks in advance!
 
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Old 08-19-2014, 06:39 PM
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I think you're pretty much set with the info you have, try to find a 94 or newer E4OD since there were several improvements made in that year, it should also be an OBD I in order to be compatible with yours, otherwise you'll need to swap the solenoid pack, using yours.
 
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Old 08-19-2014, 08:56 PM
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Are there any compatibility issues with different years? For example, '88 beams and D44, 94 E4OD, and 91 BW1345? I was planning on picking things up here and there as time and money permit. Are there any design improvements to the suspension components in later years as well?

I do have a few questions for the experts:

Is the D44 limited slip or should I plan on doing that?

Should I pull the diff out of the donor truck also? Same reason, limited slip vs my open (I think) diff.

Are there any differences in brake lines? I will probably just get some steel braided, will the ones from a 4x4 f-350 work?

Thanks in advance!
 
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Old 08-19-2014, 09:36 PM
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Stick to F-150 parts if you want direct drivetrain interchange, the 88 is useable but it's an odd year regarding the D44, you can read about it in the front end rebuild link in my sig, it's a comment from another member there. Do you think you'll need limited slip?, remember that now front and rear gearing need to match, that could be a good reason to take both axles from the same truck.

P.S.: The Dana 44 TTB isn't usually a limited slip axle.
 
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Old 08-19-2014, 11:52 PM
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Cool thank you! I am pretty new to the off roading stuff but a few friends have sort of gotten me into it. I have built lots of fast street cars though so getting dirty is nothing new. I've had my truck for many years now but just used it as a Home Depot / dump run sort of truck. I am modding it now though and having a good time
 
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