Hey everyone.

I'm thinking about converting my 2003 E-350 cargo (7.3 L Diesel w/ 4R100 trans) into an adventure crawler 4x4. Budget is an issue, of course, so I'd like to get some opinions on what kind of parts I could snag from the junk yard and what I should buy new. Specifically, what are some thoughts about getting a transfer case and the front axel from a pick-n-pull? What should I keep my eye out for? I think I have enough skill (combined with youtube videos) to lift the rear suspension, put in a transfer case, and reattach the drive shaft after I have it professionally cut. However, for all intents and purposes, I have no welding experience. I'd probably work with a shop to install the front axel and lift.

I was looking to sell my van and just purchase a 4x4 van, but it looks like the cost of converting my existing van is much less expensive. Also, I love my van! I'd like to turn this into a long-term project. So, I'm thinking I could install just the transfer case and modify the drive shaft to start, with zero consequence other than reduced fuel efficiency.

Anyway, I'm in the ideas gathering phase. New to the forum and new to the concept of van life. Please feel free to point me toward additional resources.

Thanks

About my 2003 E-350:

I bought it last February with 156K miles on it. I changed the rear brake pads, had all four rotors shaved, replaced the front calipers, and flushed the lines. Holding off on replacing the rear calipers for now, but its on the short list. Did an oil/filter change. Replaced the fuel filter (would also like to install an inline filter that is much more easily accessible. Thought?). Replaced air filters. Replaced the main battery, and I should also replace the aux battery. In doing this work, it seems as if the van was well maintained previous to me owning it.

Dreams:

Want to add a topper, class IV hitch, bumper package with winch plate and etc., solar system, and deck out the interior for off-grid camping. Thinking to spray exterior with bedliner. I'd love ability to take this thing everywhere to include job sites where I can sleep in the van and avoid expensive hotel stays. Like I said, long term project here.

 

Have you checked out Ujoint Offroad?

 

Yes, I drool all over their webpage. They're on the opposite coast from me though. Might be a great reason for a road trip someday.

Thanks!

 

I believe you can get most of what you. Eed for a co version minus the axle if you wish to DIY.
There's another that I believe is Weldtec.

 

You're already behind the eight ball then---what you have planned or desire is NOT budget friendly.

Try this site: SMB. Plenty of other DIY's who've trod the path you're hoping to travel.

Back to the budget----none of what you'd like to have comes cheap or easy----read through the above linked forum, spend as much time there as you can, ask questions---those there have been there, done that and have a wealth of info you might find useful.

HTH

 

Thank you!

Yeah, I'm aware that what I'm proposing is literally dropping upwards of $20k into a $5k vehicle. Long post short, where should I spend the money vs. where can I shave a few dollars?

I'll definitely check the links you've suggested.

Thanks again!

 

Keep your eye on eBay ... picked up my 93 E350 Quigley with 100K miles for $4.5K ... granted, I’m currently in the process of a long overhauling journey, but I’ll have less than $10K into it aside from the purchase price and could probably sell it for near double that, but that’s because I do all my own work.






point is, the only to save money on this adventure is to do most if not all the work yourself and put the saving into the dream checklist items ... that all starts with either doing the U-Joint install yourself or buying an already converted van in need of some TLC.

Good luck!

 

Thanks!

I’m totally into doing it myself, though I have very little experience. Would you say that making these modifications are pretty straight forward? I’m pretty handy with the proper tools, but It would be a pity if I ruined my van because I did something way outside my wheelhouse.

sweet photos!

 

I haven't done this, so take this for what (little) it's worth. But it seems to me that putting a front drive axle under a van is one of those "if you have to ask if you can, then you can't" sort of things. Unless there's a kit available (is there? I kind of doubt it but I don't really know) getting the front suspension put together seems like a job that would require more than just being pretty handy with tools. I think you'd be better off finding a Quigley that already has that tricky part done and putting your labor into fixing it up (like FastCougar is doing).

But again, I haven't done this, so I'll certainly defer to anyone with direct experience on a 4WD conversion.

 

My understanding is that there are kits available. A Dana 60 front axel fits perfectly for my van. It gets a bit tricky when you have to cut out the front suspension, modify the crossmember holding up engine, weld on a structural reinforcement, and weld points to attach the leaf springs for the lift kit. I’m fairly confident that I can add the lift kit, but when it comes to cutting and welding the frame, I’m almost positive that you’d need a professional organization backed by an engineer to certify it for the road. I have no idea how to weld and I wouldn’t start on my frame. Ha!

 

Keep in mind a lot of these "kits" are usually a bunch of parts needed to do the job as intended but they DO NOT typically come with a how-to DIY manual---they assume you have some knowledge of what's involved. If you're hell-bent on this look around on the SportsmobileForums.com site----there is a wealth of knowledge and experience to be found there.

 

Assuming your van has the twin beam front end like the older ones I think you could put a TTB 4WD front end in without a bunch of modding, like what all the earlier F series used and there are plenty in the junk yards. Not as strong as a straight axle, but it's 4WD, might be a bolt-on, and has the ability to ride nicer.

 

Do-It-Yourself Long-Travel TTB- Off-Road Magazine

 

No. It is no a direct transplant. Frame width is different and the pivot points are reversed on the van the driver side arm is in front of the passenger. On the 4x4 trucks is the opposite.

There are DIY kits to fit an F350 front axle. U-joint uses leaf springs. MG Metalworks (ExpoVans) and Timberline use coil springs. I did mine with the Expovan kit.

The cheapest way to get a 4x4 van is probably to find a veeeeery good deal on a used one, they do exist, but are hard to find. If you do it yourself, whatever you plan to spend will be increased by 50% in a heartbeat. Whatever time you plan to spend, multiply it by 4. If I were to build another van it will take me 1/3 of the time and effort, it is a very hard learning curve, where to cut, how to move this,...

You may think that stating with a beat up van that you can get for cheap is a good starting point since you are rebuilding transmission, changing axles, suspension,... but then you start finding other issues unrelated with the conversion that will slow you down. I'll recommend to start with the best van you can afford and enjoy it from day one and do little changes as budget and time allow you: Buy and clean the van and fix any issues, six month later buy the front axle and overhaul it. nine months: fit the front axle and lift the rear. Following year, shorten the gas tank,...convert the transmission and fit the transfer and get the driveshafts.

Not for the faint of heart.

 

Wise words, thanks for your input. I'm really satisfied with my van. I bought it about a year ago for work, and now I'm in a good position where I can begin to convert the interior for an adventure mobile. So, I've been going through and making repairs and doing maintenance, and I've come to find that it's been well taken care of. Better than I anticipated after I initially inspected it before buying. Anyway, love my van!

Part of me just thinks I ought to spend the next few years setting aside some money so I can have a shop do the entire job. However, I really like the idea of doing what I can on my own and/or with help. I really like your recommended breakdown of how I should proceed. I'll keep that under consideration.

Lastly, what's this business with shortening the fuel tank? Not the first time I heard of this, and It seems as though it's not in the way of anything. Why is this necessary? Do you physically cut a section out, or do you just buy a different tank?

Thanks again!