Hey to all the Ford people out there. Its been a long time since Ive been on this site, and its nice to be back. Hopefully this is posted in the right area.

Background: Anyway, I have decided to convert my 2002 Ford F-250 Superduty from 2wd to 4wd. Before you guys even say it.... I am not trading this one in for a 4wd. This truck is paid off completely and has sentimental value also. The truck has the 10.25 Sterling with a V10 and AT. Just FYI, my goal is to have a 6" lifted 4wd Superduty that will see only moderate off-roading.

Questions: Its obvious the first part I need, and probably the biggest, is the front axle assembly. According to my research, the Superdutys came with the Dana 50 or Dana 60 out front. I realize the Dana 60 is probably stronger, but I know the 50 should be easier to find. Again, only moderate offroading, so the Dana 50 should be fine IMO. I'll figure out what gears I need later. Next, is the transfer case, NP 271 I believe was used until 05. Then I need driveshafts, front springs and brackets, manual hubs (are there oem auto hubs?), spindles, 4wd switch in the cab, ecu for 4wd, wiring harness for the transfer case, brake stuff and steering linkage (is it different?) And, what esle guys?

I know this swap will not be easy, but I am definitely serious about this. Right now, I need to know what parts I need and WHAT IS THE OVERALL LENGTH of the front axle FLANGE TO FLANGE?

BTW, if anyone is getting rid of an axle or case, let me know.

Thanks for the help ahead of time here.

Greg
desert_rat44

 

with the amount of stuff you need you better look into buying a second truck from a insurance auction. the axle alone goes for 2,000.00 used. the t case another 1500.00. you also need the tranny from the 4x4 truck unless you want to dismantle yours and mount the t case. the steering is different. you can get a insurance truck for about 6,000.00. get all the parts you need then resell it.

 

I know you don't want to hear it, but I'm going to say the same thing 'gashog said.

Its just not worth it, or even feasable, to do a conversion on a truck like that.

 

Get lots of tools, money, and learn how to do all this. Why not another axle like a dana60 from an earlier vehicle? Also, why not another tcase? I hate electronic shifting tcases and tell everyone that has had theirs fail to convert to manual shift. No matter what this is going to cost like $10K to complete unless you have all the stuff and do all the work yourself. It seems you want a challenge. Estimate cost of money and time and then triple those estimates. Good luck.

 

Let me start out by saying that I will be doing all the work myself. I am a student at UTI, and will starting their Ford Cert. program soon. That and the fact that Ive wrenched on a lot of vehicles.

I have also priced the dana 60 at $2000. If I can find one at a wrecking yard its a lot less. As far as the transfer case, Ive found out thats rebuilt for $700, new costs $1200. Again, these are the prices Ive found. And when it comes to mounting the transfer case, Im assuming I can use my same transmission, only bolting up. Will I need a different cross member?

I have thought about an older front axle and welding on the spring perches. This is why Ive asked the total length of the front axle from flange to flange.... (Still need to know :-) ) What would be EXTREMELY helpful is for me to photograph someones 4x4 Superduty. Any volunteers? I live out in Acton, California. So, anyone who lives in Southern California and would like to help.... message me. Or if someone has a digital camera....

To answer another post, I have thought about going to a manual shifting tcase, BUT.... Ive never done one before... and thought it would be easier to stay as close to OEM as possible. Is there a manual NP 271? or whats a different tcase that bolts up to the Superduty transmission (I cant remember the code)

Lastly, I want to stress that I am very realistic about this swap, and I know it will be difficult, and fairly costly. My total budget for the swap is $4000. And I have most of the necessary tools already. Thanks for the posts, keep them coming.

Greg
desert_rat44

 

You can get manual transfercases in superdutys. There actually very common unless your looking in a lariat

 

Thats good to know. I will start looking for a manual case then. I just know that my friend has a 99 Superduty 4x4 and he has an electronic tcase. I guess I assumed that anything newer was electronic. Any other help?

Greg

 

Too bad you didn't post this about three weeks ago... a super duty front axle assembly was sold on ebaymotors.com. And it was quite a bit less than $2k as well, though it was a "no shipping" auction.

Superduty anything is hard to find in junkyards... at least near me in NJ. One "we pull it and rape you" yard had an F350 superduty crewcab with a V10 in it, and I inquired to various prices and for what they wanted for the parts... 20% more in price I could buy new from the local Ford dealer.

Me, I'm a "I'll pull it and drag it out on my garden cart" kinda guy.

 

Yeah, I'm the same way. If I could go to a yard and pull the parts, I'd be over joyed (spelling?). Anyway, I did see that ebay auction, not sure what it went off for. This whole thing will probably take me a long time to perform, mainly because of gathering all the parts. Which brings me to this forum, so if anyone has or knows the majority of what I need, or what the differences are between 2wd and 4wd trucks.... post something. Please. Thanks to those who have posted comments.

Greg

 

.............bump

 

OK, one question. WHICH transfer cases will bolt up to my automatic transmission? this includes both manual and electronic tcases.