2wheel drive to 4x4 conversion
Posting Guru
Joined: Oct 2010
Posts: 1,199
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From: Missouri
Well crap. I just rebuilt my c-6. So you are saying I pretty much wasted my money on it? That seems weird that I cannot bolt up a t-case to it. Okay, so if I found a donor 4x4 trans and t-case, and took my truck to a shop would they use the transmission thats in the truck and swap in a few parts from the donor and bolt up the t-case? I wonder what that would cost. I guess I will do some calling around.
Fleet Mechanic
Joined: Jul 2011
Posts: 1,916
Likes: 4
As I understand it, the main difference between the 2wd and 4wd transmissions in these trucks isn't the parts that are physically in it, rather the bolt pattern on the output shaft at the back of the transmission and the length of the output shaft. My New Process 435 4-speed in my truck has an asymmetrical butterfly-shaped bolt pattern, like a trapezoid. 2wd New Process 435's use a square bolt pattern.
With the C6 though, you guys were right on in that it's the output shaft that needs to be changed. It looks like the 4wd C6 has a shorter output shaft. I'm not sure if the bolt pattern on the output shaft of the transmission would be different, I don't think it is. If you want to find out, best way to go would be to call to a transmission shop and ask them if it's different.
https://www.ford-trucks.com/forums/8...c6-to-4wd.html
Something else that needs to be considered too is married vs. divorced transfer cases. From that thread above, it looks like a New Process 208 transfer case is a direct bolt-on. The 208 IS a married case, and I have one under my truck behind the NP 435.
With the C6 though, you guys were right on in that it's the output shaft that needs to be changed. It looks like the 4wd C6 has a shorter output shaft. I'm not sure if the bolt pattern on the output shaft of the transmission would be different, I don't think it is. If you want to find out, best way to go would be to call to a transmission shop and ask them if it's different.
https://www.ford-trucks.com/forums/8...c6-to-4wd.html
Something else that needs to be considered too is married vs. divorced transfer cases. From that thread above, it looks like a New Process 208 transfer case is a direct bolt-on. The 208 IS a married case, and I have one under my truck behind the NP 435.
Moderator
Joined: Jan 2001
Posts: 56,983
Likes: 2,736
From: Virginia
The output shaft is different as well as the tailshaft piece. There is not a tranny made that fits in a Ford truck, where you can just insert a shorter shaft and take the tail housing off and bolt up the transfer case. They all have to be torn down pretty much completely for this to be done. On your c6, they would have to do a complete teardown starting at the torque convertor, and work their way back.
So to do this conversion using your tranny, you are looking at the same labor you paid to get it rebuilt, plus the cost of the parts for the conversion. And guess what? The conversion parts will probably be on the used tranny from the donor truck, so that tranny has to be torn down to get them. You might as well sell your rebuilt tranny, roll the dice on the donor tranny or just get the donor rebuilt.
So to do this conversion using your tranny, you are looking at the same labor you paid to get it rebuilt, plus the cost of the parts for the conversion. And guess what? The conversion parts will probably be on the used tranny from the donor truck, so that tranny has to be torn down to get them. You might as well sell your rebuilt tranny, roll the dice on the donor tranny or just get the donor rebuilt.
New User
Joined: Oct 2011
Posts: 4
Likes: 0
To make sure the gearing stays correct front to rear may have to use the rear end from the donor also? And if a bronco was being used I assume the rear end would bolt up to the f150? I am interested in doing a 4wd swap into my 2wd 86 F150 also.
Fleet Mechanic
Joined: Jul 2011
Posts: 1,916
Likes: 4
You could probably just pull the gearset out of the rear end from the donor vehicle if the axles are the same if you don't want to go through the trouble of dragging a rear end out from underneath a truck. Both of them have their own work involved.
Bronco's are more or less (during and after 1978 for the full size models anyway) the same as an F150. Same axles, front ends, front clips, doors, most interior components, taillights, etc. I think of them more or less as a truck with a camper shell and an extra seat. So yeah, the axle will bolt right in.
I'd like to get my hands on a 78 or 79 bronco and swap a 73 to 77 grill on, but that's just me.
Laughing Gas
Joined: Feb 2011
Posts: 1,147
Likes: 6
From: Vine Grove KY
The output shaft is different as well as the tailshaft piece. There is not a tranny made that fits in a Ford truck, where you can just insert a shorter shaft and take the tail housing off and bolt up the transfer case. They all have to be torn down pretty much completely for this to be done. On your c6, they would have to do a complete teardown starting at the torque convertor, and work their way back.
So to do this conversion using your tranny, you are looking at the same labor you paid to get it rebuilt, plus the cost of the parts for the conversion. And guess what? The conversion parts will probably be on the used tranny from the donor truck, so that tranny has to be torn down to get them. You might as well sell your rebuilt tranny, roll the dice on the donor tranny or just get the donor rebuilt.
So to do this conversion using your tranny, you are looking at the same labor you paid to get it rebuilt, plus the cost of the parts for the conversion. And guess what? The conversion parts will probably be on the used tranny from the donor truck, so that tranny has to be torn down to get them. You might as well sell your rebuilt tranny, roll the dice on the donor tranny or just get the donor rebuilt.
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cbremer
1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks
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Mar 31, 2000 08:47 AM
