2wd to 4x4 conversion
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Junior User
Joined: Sep 2009
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From: Northern Az
2wd to 4x4 conversion
Well I have been looking for a decent crew cab 4x4 for awhile now. They either beat to hell or they want crazy prices for them. SO, I have decided to look into converting my 1990 crew cab f350 into a 4x4 using my 1989 f250 extra cab as a donar. Here is the problem. The 1989 is a c-6 and the 1990 has a built e4od. Can I use the transfer case from the c-6 on the e4od? What kind of problems will this create? I would love to hear from anyone who has done this. Or anyone with knowledege of what I will run up against. THanks Van
Lead Driver
Joined: Feb 2002
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From: Greater Austin, Texas
The xfer case can be used, but not on your 2wd E4OD. You need a 4x4 E4OD or you need to replace the extension housing on your trans with the 4x4 part. Unfortunately, you will need to completely disassemble your trans to do this.
Senior User
Joined: Mar 2007
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From: Erie Pennsylvania
The e4od has to be completely taken apart to put the adapter for the transfer case on? I am going to be doing a 2wd to 4wd swap this summer, and I was hoping to just unbolt the tailshaft and bolt up the t-case adapter...but it sounds like its a little more complicated now.
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Joined: Jan 2014
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Honestly, you need to essentially replace everything but the engine. I.E., need a 4wd tranny, t-case, front diff, etc.
IMO, either find a wrecked 4x4 or just upgrade to a slightly newer truck. Will save you a LOT of headaches.
IMO, either find a wrecked 4x4 or just upgrade to a slightly newer truck. Will save you a LOT of headaches.
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Junior User
Joined: Sep 2009
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From: Northern Az
It does sound like a lot more work than I thought. I may go ahead and swap the whole drive train out of the 89. The c-6 has been built up as well. I have a overdrive unit that I just need to get all the controls for. If I did that, I could just swap the tranny, transfer case and axle from the 89 to the 90 and have the crew cab with the gear vendor and the c-6. and put the e4od in the 89 and sell a 2 wd e40d to recoup the costs of the controls and adapter for the gear vendor. Ill have to price it all out and see if it makes sense. What about putting the e4od in the 89, is it just a matter of swapping in the tranny and control box, or is there more to it? Thanks Van
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Joined: Apr 2004
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From: Washington
As above the 4x4 version of most trans have an adapter and a short shaft out the back made for bolting an Xfer case onto. Most 2wd have a slip yoke of some sort and tearing the trans all the way down is usually a must to replace either.
Also 3/4 tons have a TTB set up with smaller u-joints and a different front driveshaft compared to the solid axle F-350s.
The 2wd trans will work in a 4x4 with a modified rear driveshaft BUT there will be no front wheel drive and trying to sell a truck with a 4x4 front axle and no xfercase, guessing bottom dollar.
Also 3/4 tons have a TTB set up with smaller u-joints and a different front driveshaft compared to the solid axle F-350s.
The 2wd trans will work in a 4x4 with a modified rear driveshaft BUT there will be no front wheel drive and trying to sell a truck with a 4x4 front axle and no xfercase, guessing bottom dollar.
Last edited by bobracing; Feb 25, 2014 at 08:04 PM. Reason: Edit for having comprehension problems.
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Junior User
Joined: Sep 2009
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From: Northern Az
As above the 4x4 version of most trans have an adapter and a short shaft out the back made for bolting an Xfer case onto. Most 2wd have a slip yoke of some sort and tearing the trans all the way down is usually a must to replace either.
To answer the question, a 4x4 E4OD will NOT work in a 2wd configuration without lots of work.
Also 3/4 tons have a TTB set up with smaller u-joints and a different front driveshaft compared to the solid axle F-350s.
To answer the question, a 4x4 E4OD will NOT work in a 2wd configuration without lots of work.
Also 3/4 tons have a TTB set up with smaller u-joints and a different front driveshaft compared to the solid axle F-350s.
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Elder User
Joined: Dec 2009
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From: Ohio
Why don't you sell the 89, I assume it's a runner, and use the proceeds to fund your conversion?
Probably the single most expensive part will be your transmission. As others have stated it needs tore down to convert to 4x4, completely. On the E40D the output shaft is like the first thing in and last thing out. Besides that expense you have to buy the adapter/output shaft. Either that, or dump your tranny and go find the factory made unit.
If you get past that, and have any mech. skills, the rest is not that big of a deal. An NV271 is not hard to come by, and relatively inexpensive.
Now if you REALLY want to use what you've got, you can yank the axles and springs and what-not, part out the rest, and find yourself a divorced transfer case to hang under there. Then all you need to do to your tranny is have a short shaft made to connect the two. Not my favorite method, but it worked for Ford in their 3/4 ton 250s with the NP205s.
A conversion like this is almost never as simple as just bolting things in, unless you want to toss a bunch of money at it, but if your '90 is REALLY want you want, then in the end it can be worth the various hassles.
Probably the single most expensive part will be your transmission. As others have stated it needs tore down to convert to 4x4, completely. On the E40D the output shaft is like the first thing in and last thing out. Besides that expense you have to buy the adapter/output shaft. Either that, or dump your tranny and go find the factory made unit.
If you get past that, and have any mech. skills, the rest is not that big of a deal. An NV271 is not hard to come by, and relatively inexpensive.
Now if you REALLY want to use what you've got, you can yank the axles and springs and what-not, part out the rest, and find yourself a divorced transfer case to hang under there. Then all you need to do to your tranny is have a short shaft made to connect the two. Not my favorite method, but it worked for Ford in their 3/4 ton 250s with the NP205s.
A conversion like this is almost never as simple as just bolting things in, unless you want to toss a bunch of money at it, but if your '90 is REALLY want you want, then in the end it can be worth the various hassles.
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Thread Starter
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Junior User
Joined: Sep 2009
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From: Northern Az
You are probably right. Selling the 89 would make the most sense. I just have a hard time parting with a great truck just because it isnt exactly what I want. The 89 has a crap paint job, but other than that it is one of the best trucks I have ever owned. Runs and drive great, Banks turbo set-up, etc. Hate to see it go. Plus it is 4x4 so all the parts i need are there, I just need to put it all together. Maybe I can sell just the c-6 and use the money to buy a 4x4 e4od. I put $1600 into the c-6 last summer to make it bullet proof. I dont know what I could get out of it, but maybe at least enough to buy an e4od, and then have that built. Or as I said before maybe the c-6 with a gear vendor is the way to go. I guess Ill have to figure it out. Van
Tuned
Joined: Apr 2010
Posts: 320
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From: Vancouver Island, BC
IMO it would never be worth all that effort to make your F350 a 4x4 with a Dana 44 TTB front axle from your F250. I think the conversion sounds like a great way to make the truck you can't find at an affordable cost, but you gotta make it a Dana 60 kingpin if you go to all that effort. You could also consider looking a F350 crew cabs with a 460 and doing an engine swap. The 460 trucks are often way cheaper. This brings it's own set of challenges though.
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Junior User
Joined: Sep 2009
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From: Northern Az
IMO it would never be worth all that effort to make your F350 a 4x4 with a Dana 44 TTB front axle from your F250. I think the conversion sounds like a great way to make the truck you can't find at an affordable cost, but you gotta make it a Dana 60 kingpin if you go to all that effort. You could also consider looking a F350 crew cabs with a 460 and doing an engine swap. The 460 trucks are often way cheaper. This brings it's own set of challenges though.
Tuned
Joined: Apr 2010
Posts: 320
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From: Vancouver Island, BC
I meant buy a F350 4x4 crew cab with a 460 for cheap and put in a 7.3L
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Junior User
Joined: Sep 2009
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From: Northern Az
My understanding is the e4od from the 460 wont bolt up to the idi so I would be back to the same problem.
Tuned
Joined: Apr 2010
Posts: 320
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From: Vancouver Island, BC
yeah for sure. the bell housings are different. If it were me I would try to find a ZF5 4x4 transmission from a diesel. but yes, either way you don't have all the parts you need.