4x4 Conversion
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Senior User
Joined: Jul 2004
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4x4 Conversion
I know its been asked alot and ive researched it alot but i still have a few questions. I have a 96 F150 4x2 that i really want to convert into a 4x4. from what ive read, if i find an 80-96 f150 all the parts will bolt right up, but i want to have manual 4x4 shifting and plan on warn locking hubs, what years feature this? also can i just have the tailshaft on my current tranny adjusted or whatever has to be done to it to mate with the transfer case and just steal everything else off the donor vehicle? sorry to ask this question again but i just wanna be sure =\
Postmaster
Joined: Jul 2003
Posts: 2,711
Likes: 2
From: Pittsburgh
what transmission are you running? if it's an auto you can have the tailshaft replaced and a new extension housing put on, but that requires completely disassembling the unit. on a manual no such luck, the tailhousin patterns are different between 4x2's and 4x4's. might be able to drill one or the other to match, never tried it.
Manual cases that will bolt up can be found from 96 back to the early 60's, and as for manual hubs, ANY D44 will accept them. Just buy a new set, the old ones are wasted or close enough (play it safe, it's only $90).
It's easiest to work from a complete parts truck. I got mine for $100 to do the swap. Swap tranny, case, everything (axles included), to make sure the ratios match and all that jazz.
It's only worth it if you do all the work yourself and get a parts truck super cheap (i'd recommend rebuilding everything while it's out, saves in downtime later).
Now i'm getting ready to swap in a solid axle. Never ending project is what it is
Justin
Manual cases that will bolt up can be found from 96 back to the early 60's, and as for manual hubs, ANY D44 will accept them. Just buy a new set, the old ones are wasted or close enough (play it safe, it's only $90).
It's easiest to work from a complete parts truck. I got mine for $100 to do the swap. Swap tranny, case, everything (axles included), to make sure the ratios match and all that jazz.
It's only worth it if you do all the work yourself and get a parts truck super cheap (i'd recommend rebuilding everything while it's out, saves in downtime later).
Now i'm getting ready to swap in a solid axle. Never ending project is what it is
Justin
Lead Driver
Joined: May 2000
Posts: 9,236
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From: Senoia, GA
i am gonna have to suggest getting an F350 and swap all the parts from a one ton! that way you will be so many steps ahead of many ppl on here. all the parts will swap out to an F150 (except the coils to leafs which will be the only major fabbing, and it isn't all that hard). you will save a LOT of money too!
on the t-case i know you hear everyone suggest it and it seems overrated but it is hard to beat the cast iron cast of the 205! i am actually about to swap one in in my truck this weekend.
-cutts-
on the t-case i know you hear everyone suggest it and it seems overrated but it is hard to beat the cast iron cast of the 205! i am actually about to swap one in in my truck this weekend.
-cutts-
Post Fiend
Joined: Jan 2000
Posts: 5,330
Likes: 17
From: Dryden, ON, Canada
Something like this would be well worth the investment:
http://cgi.ebay.com/ebaymotors/ws/eB...488711792&rd=1
That's one CLEAN 460... Heck, other than being bare bones, it's a nice truck too...
http://cgi.ebay.com/ebaymotors/ws/eB...488711792&rd=1
That's one CLEAN 460... Heck, other than being bare bones, it's a nice truck too...
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Senior User
Joined: Aug 2004
Posts: 201
Likes: 0
From: Los Angeles
i have a complete convertsion for it
my dad was going to swap his truck to a 4x4 but then i just bought a 4x4
if you want it just make an offer and honestly i just kinda want it out. it came off a 1983 ford F 250
my dad was going to swap his truck to a 4x4 but then i just bought a 4x4
if you want it just make an offer and honestly i just kinda want it out. it came off a 1983 ford F 250
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btw i have the E40D tranny i believe
Postmaster
Joined: Jul 2003
Posts: 2,711
Likes: 2
From: Pittsburgh
yep. it's easiest if you have an auto tranny to get a truck with an auto (otherwise you have to do a clutch setup). I'm partial to the '80-83's since you get a 9", but any wil work. OH!! AVOID 87"S LIKE THE PLAGUE!!! They have goofy one year only brakes and spindles. talk about $$.
Justin
Justin
Postmaster
Joined: Jul 2003
Posts: 2,711
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From: Pittsburgh
no problem. it's a fun project. took me about 6 months, but that was spending $50 here and $50 there while rebuilding everything. The actual swap only took about 8 hours.
As my truck sits i have almost $3000 into it including teh purchase price of both the trucks (500 and 100). The actual conversion cost about a grand. Then tires, lift, all teh fun stuff
I have the same amount in tires and wheels as it cost to swap over 
Justin
As my truck sits i have almost $3000 into it including teh purchase price of both the trucks (500 and 100). The actual conversion cost about a grand. Then tires, lift, all teh fun stuff
I have the same amount in tires and wheels as it cost to swap over Justin
Last edited by hoxiii; Sep 3, 2004 at 01:09 AM.