Hello everyone,
I live in Boise, ID and have begun my journey to convert a High Top E150 into a 4x4 mild-off roader. The van has 342000 miles on it with all but the last 10,000 by the first owner. I'll be converting the interior into my own simple camper van and with 4x4 I'll be able to explore the back country.

I choose an unconventional route to go 4x4. I cut out the entire front frame and axle assembly from a 2005 F150. I have since grafted that into the van. This past weekend I completed the initial grafting and the van is now sitting on a F150 front axle. I'm also replacing the rear axle with the corresponding axle from the F150. The axles have 3.55:1 gears in them. I'm also using a BW4406 electric shift transfer case. I'm in the middle of building my own controller for the shift motor.

2005 F150 4x4 front axle benefits:
1) Slightly higher axle capacity compared to van axle
2) Fantastic road manners - F150 IFS is very nice!
3) Rack and pinion steering!
4) Engine fits with adequate clearance
5) vacuum actuated hubs (I'm aware not everyone agrees with this, but my experience with F150s is all positive)

I'll be cutting the bumper and crush zone ends of the van frame off and welding them onto the F150 frame. This will preserve the crush zones Ford engineered into the van and help protect me if I ever end up in a bad accident. Will also allow me to preserve the front body mount points and the bumper attachment points and locations/alignment.

Anyway, hopefully the attached pictures give a little insight to the swap so far.


Van frame removed. Engine is supported by the a-frame support.

Van frame ready for attachment to F150 frame.

F150 frame ready to attache to Van frame. Engine mounts ready for the engine.

Front of van view with F150 frame

On the f150 front axle for the very first time.

 

Cool project, you were thinking outside the box on this. Hopefully you continue to update this thread.

 

Very nice conversion puzzle.
Was there much difference in the frame channel widths for match up ?

Looking forward to some photos of the graft.

Today, I took my '78 E250 home-brew 4x4 Trekker van for a spin with a big smile.
Oct of 2022 I purchased new rubber for it and scaled down from BFG all-terrains in 315 size, down to a 285/75-16 BFG mud terrains.
My F250 front Dana 44 rides on '84 Wagoneer front springs and frame shackles. Makes for a nice cow-trail crawler when needed.

I must agree with you that some of the new chassis and suspension may as well get Re-Purposed.
Pick-n-Pull is a wonderful big-boys candy store for parts picking.

I remember the days of the Quadra-Van's, and there were several running around in my area 30-yrs back.
(the front axle under my van came from a donor '86 Chev Quadra Van that had an engine fire). ford F250 axle hsg with Gm knuckles on out w/ 8-lug.

 

The exterior width of the frames behind the engine is about 1" narrower. The inside is more like 3" narrower. The F150 frame is significantly beefier than the van frame. The difference is even greater at the axle line. The van frame widens while the f150 frame stays the same. This made fitting the engine a bit of a challenge. Turned out to be totally doable though!

I'm looking forward to enjoying driving my rig once it is done. I'm working the rear axle right now.

 

Jan. 30, 2024
Thank you for reporting back with the frame differences.. Here in Calif., according to DMV, and CHP, the front 1/3 of the frame dictates year model registration.
Very nice work on your puzzle solution to use the F150 setup. I have not yet owned a newer Ford modular SOHC engine.

Keep us peeps informed on your progress. I'm sure there may be other's out there watching closely. LoL

 

I have the rear axle completely removed.
I'm currently working on removing the old spring mounts from the frame. Given the location between the body and the frame it is time consuming to get the old huck rivets cut and drilled out. I have one side almost done.
The replacement axle has been reconditioned with new seals, new e-brake hardware and pads and new studs.
I have determined the placement of the new spring perches in order to get the appropriate axle placement and body lift.
Looks like this weekend is a rainy weekend for me so I'll probably start working on the new spring mount perches.

A few pictures just to show where I'm at.


no rear axle - pic 1

no rear axle - pic 2

I've also decided to go with a 6R80 transmission instead of the E4OD. I have a 4x4 F150 2017 6R80 transmission in transit right now. I'll use the USshift 6 computer to control the tranny. Adapter is on hand to marry the small block to the 6R80.

My replacement engine is starting to come together as well. I have the replacement small block (351W) on order and should get that in about 2 months. I'll be putting an AFR 165 head on as well as a comp cams camshaft.

I'll be running the engine with a 5.0L MAF computer from 95 after completing the wiring harness changes required to convert to MAF from SD.

 

Way cool project BTW.


Are you using a later model rear axle too?



You should investigate using a Stinger PimpXs controller which can do both engine and trans, it plugs right into the factory Ford harness, doesn't require MAF and is tunable. Your engine combo will require tuning even with MAF.

 

Yes - the rear axle is from an 07 F150. Primary reason was to get an axle with disk brakes and secondary is significantly less miles! Putting the F150 rear springs in as well since the van's were sagging significantly.

As far as I can tell the PimpXs controller does not work on the 6R80. If that is not the case then I'm definitely interested in it. However, all my research did not uncover any ability to mange the 6R80.

 

Yeah I wondered that too, I like your idea of using a 6R80 though so if it's not possible then separate controllers it is, the basic Pimpengine only) is available for the SD version though and would save you converting to MAF and finding a tuner for it... which is getting harder by the minute.

 

Can you use Forscan or a generic OBD scanner with a customized setup like that? Which module hosts the odometer?

Sixto
07 E350 5.4 197K miles

 

THe speedo cluster is it's own separate device in these old vans same as everything else, there is no single unified communication system connecting all the different modules together so the short answer is no.

 

Just wondering how the rear axle assembly install is coming along.
I've been waiting for winter to pass so I can begin on some body and paint work on my '78 E250 4x4 trekker van. Been a looong cold winter.
My wife and I have burned thru 5-chords of pine and 1-chord of Live Oak, and are now into our Back-up supply for March.

 

I have been making slow progress. The weather has been really wet here and I'm working on the van outdoors. I have accomplished the following:
- Removed the old axle and springs
- Removed the spring to frame mounts. That was harder than expected. Those rivets are hard to get to and even harder to drill out.
- Put new seals in the F150 rear axle
- Rebuilt the brakes on the F150 rear axle
- Removed the gas tank - required to remove the driver side front spring to frame mount
- Built new spring to frame mounts for the F150 springs
- lightly welded mounts together
- Tested the ride height with the F150 springs. Nailed it! Good clearance all around and when loaded up with gas and my camping stuff the front and the back should be almost level.

Next up:
Finish fabricating the shock absorber to axle mounts and to frame mounts. I'm putting the shock absorbers between the frame and the springs. I have just enough clearance to make this work. I'm using the F150 shocks as they have more travel than the E150 shocks have.
Once the shock absorber mounts are finished and tacked into place I'll pull everything back apart. I'll finish welding up everything and give all a coat of paint. Then I can re-install and wire in the abs sensor and connect up the brake lines. That should complete the rear axle install.
So - another couple of weeks before that is done...

 

Thought I would give an update since it has been a while ...

Complete:
- Rear axle swap 100% done
- Front crush zone framing welded back in place and ready for the bumper to be bolted on
- Factory Wiring harness updates completed
- Engine wiring harness updates completed for conversion from batch fire to sequential injection
- Transmission computer mounted and fully wired into place (this is for the 6R80 transmission)
- Electronic on the fly shift BW 4699 transfer case computer and all associated wiring in place and working! That was a huge project, but it works and works well. I even think I have the shift on the fly portion working properly to go from 2H to 4H without having to stop. I am controlling the front hubs separately from the transfer case. So, I'm able to be in 4L if I want the low range for slow off roading without the front hubs being locked. I have the transfer case shift to neutral working as well.
- Replacement engine is almost fully built
- 6R80 to Ford Small Block adapter built and complete - ready to bolt the transmission to the engine when it comes off the stand
- Sold old high mile E4OD transmission - Yes - out of my garage!
- 6R80 transmission fitted with new filter - ready to be refilled with fluid
- Front brake lines and abs wires completed
- Steering linkage fabricated and in place

Next up:
- Finish engine build, mount tranny and transfer case
- Put engine back in van
- Fabricate new cross over transmission mount member (transmission mounts are different between the E4OD and the 6R80)
- Get driveshafts cut down to the proper length by local driveline shop
- Cut off front of gas tank and shorten as required to clear the transfer case
- Source and install the transmission external oil cooler
- Fabricate up the power steering pump oil lines
- Mount all engine assecories
- Put front end back together
- Final computer programming
- Test drive and break in of engine


So - getting closer!

 

Wow! Hard to believe it has been 2 1/2 months since I last posted an update.

I have a running 4x4 van with a modern transmission and transfer case. The 6R80 transmission works fantastic! I love it! 4 wheel drive works as you'd expect it to with a 2005 F150 front end and 2017 transmission/transfer case components. My custom transfer case controller works perfect.

The rebuilt engine I put together has loads of power! I know the van is heavy, but the engine and transmission combo make it "feel" like a much lighter vehicle.

The 2nd phase has begun with a complete gutting of the interior. I have a new floor in (front to back) and the "sleepers" are in place for a new ceiling.
Next up is:
- completing the ceiling
- remove and reseal all the conversion windows (3) - they all leak terribly
- put in a new headliner above the driver/passenger
- wire up some dome lights (none exist right now)
- start working on the walls

Here are some pictures to commemorate the completion of the first phase of my project.


Corner cut out of gas tank in order to clear the transfer case.

Engine/transmission adapter all painted and ready for the flex plate and transmission to be mounted up.


some assembly required

hanging perfectly balanced by the rear of the engine - preparing for rolling out the garage and into the van

Getting ready to go in

I think everything is clearing ...

Yep, going to have to go higher to clear the oil pan ...

Front shot of newly installed engine/tranny

Engine and tranny "roughly" in place before bolting down engine mounts and fabricating the tranny cross member

Front on - lots of clearance - at least matching what an F150 provides


Lots of clearance

Transfer case controller computer and relays all snuggled in behind the knee beauty panel below the dash.

Two silver switches from left to right: Transfer case computer master power Front hubs locked/unlocked Below silver switches is a 4 position rotating dial switch, 2H <-> 4H <-> N <-> 4L and next to the dial switch on the right is the LCD display which states what the transfer case computer is doing and the current gear selection