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Hi guys I was wandering how hard is it to convert a 2wd f100 into a 4 wd? If I use stock C6 gearbox and strap on a transfer case and get a driveshaft made up?
Would something like this from a local f100 wreckers bolt straight into the stock radius arm mounts and Spring location?
No, the above front axle will not bolt in. A original style 2 piece ttb 4x4 axle from a 80-96 f150 will bolt right in.
Your transmission plans will not work. You will need a 4x4 transmission. Once you get that, it will bolt in, change the rear driveshaft, add the front driveshaft and you are ready to go, all a bolt in.
P.S. You need to find out your rearend ratio, the front axle ratio needs to match. If that is a problem, just bolt in the rear axle from the donor that you get the front axle from. Check your wheel bolt pattern, some f100's had a Ford car pattern. If yours does, I would go ahead and swap the rearend out also, the 4x4 axle will have the Ford truck lug pattern.
I will back away from saying the above axle will not fit up. I see you are from Australia, they did things differently down there and that axle pictured may bolt up, we didn't have some of the features you guys have down there. I see in the picture it's a right hand drive axle, the steering box is on the other side.
Will the 4 speed Borg Warner gearbox be suitable to be used in a 4wd conversion
Only if it came out of a 4WD truck. Any 2WD tranny will have an output shaft and tailshaft housing that will not attached to a transfer case. With the right parts they can be rebuilt into a 4WD trans, but it's usually a lot better just to start with a 4WD trans.
Although if you go back old enough (early '70s?) the 4WDS trucks had divorced transfer cases, so they actually used 2WD transmissions.
And to answer the inevitable question, yes, you could get a divorced transfer case and use it with a 2WD transmission. But it involves some fabricating to make a new crossmember that's strong enough to hold the transfer case in place, then you need to deal with three new driveshafts. So stick with a more modern transfer case and get a 4WD transmission.