Converting to 4x4
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Mountain Pass
Joined: Mar 2004
Posts: 102
Likes: 0
From: Wilmington, NC
Converting to 4x4
Considering the switch. I have a 91 standard cab with the E4OD tranny. What would I need besides hubs, transfer case, front differential, drive selector, and drive shaft. Did these trucks have a differential or CV joint setup? Is this a practical job or too complex. I am not looking to have it off the road for a month is what I am getting at. Anyone done it? What did it cost you? This is a great truck that I couldn't afford to replace so I am thinking of do it instead of getting a 4x4. Thanks.
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
Biggest problem is the 91 2 wheel drive was coil springs on the front.
The 91 4x4 had leaf springs.
I guess one way around that would be to use a Dana 44 out of an F150 and swap hubs so you could use 8 lug wheels.
Front and rear driveshafts from a 4x4 with the same wheelbase as your truck.
Front differential out of an F150 4x4 with all the mounting hardware.
F250 hubs off a Dana 44 HD to install on the F150 axle.
Transfer case, shifter and shifter boot.
If you had everything swapped out and ready to install, had a good place to work with air tools and all and an extra hand when needed it shouldn't be that bad.
I remember someone posting about this a while back.
The 91 4x4 had leaf springs.
I guess one way around that would be to use a Dana 44 out of an F150 and swap hubs so you could use 8 lug wheels.
Front and rear driveshafts from a 4x4 with the same wheelbase as your truck.
Front differential out of an F150 4x4 with all the mounting hardware.
F250 hubs off a Dana 44 HD to install on the F150 axle.
Transfer case, shifter and shifter boot.
If you had everything swapped out and ready to install, had a good place to work with air tools and all and an extra hand when needed it shouldn't be that bad.
I remember someone posting about this a while back.
Moderator
Joined: Jan 2001
Posts: 56,997
Likes: 2,744
From: Virginia
I don't believe you can convert a dana 44 out of a f150 to 8 lugs. We had a discussion about this in the 80-86 forum. There was an article on the internet about some guys converting a Bronco to 8 lug, but they had to use some chevy axle parts to do it. The brakes and calipers are the hang-up I believe.
Unless you want to fabricate spring brackets, and modify the frame to fit the front leaves, i don't think you will be able to do it.
Unless you want to fabricate spring brackets, and modify the frame to fit the front leaves, i don't think you will be able to do it.
Freshman User
Joined: Sep 2006
Posts: 42
Likes: 0
From: Heart of Canada
Stay away from the idea lol
Originally Posted by baddarryl
Considering the switch. I have a 91 standard cab with the E4OD tranny. What would I need besides hubs, transfer case, front differential, drive selector, and drive shaft. Did these trucks have a differential or CV joint setup? Is this a practical job or too complex. I am not looking to have it off the road for a month is what I am getting at. Anyone done it? What did it cost you? This is a great truck that I couldn't afford to replace so I am thinking of do it instead of getting a 4x4. Thanks.
And I also don't think it'll be a cheap project either... Diffs around here are a thousand bucks... T-case? $500 if you're lucky. And you don't even know what's wrong with these parts. A parts truck might be a smart choice, but if you can't drive it around, it's buyer beware.
If you plan it out and it seems easy, it's probably too easy lol.
If you love the truck, leave it as is and if you really do need/want a 4x4 than if you have the cash, go and buy another truck, or sell your 91 and find a big 'ol beast.
Senior User
Joined: Oct 2004
Posts: 114
Likes: 0
From: Fosen, Norway
The outgoing shaft of the 2wd E4OD gearbox is about 23 cm. And the outgoing shaft on a 4wd E4OD gearbox is about 15 cm.
We just found this out because we tried to fit a E4OD gearbox from a 2wd into my friends 4wd.
We just found this out because we tried to fit a E4OD gearbox from a 2wd into my friends 4wd.
New User
Joined: Apr 2006
Posts: 18
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conversion
I've did a conversion on my 1986 2wd f250 longbox, extended cab. the best advice would be find a similar year truck as parts and use it. I've found a 1990 f350, hung leaf springs and converted the c-6 to 4x4. i've made templates off of the donor truck and cut the front chunk of frame off for a reference too... it went well but took about 6 weeks from start to finnish and that was working on it after work and spare time. only hang up was the rear driveline, had to get one made cause the original was worn out. my home garage was well setup too, torches, grinders, etc... every thing that i needed to doo the job. you'll need a good air chisel too, to push out factory rivets after you burn the head off of them. Good luck
paul
paul
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Joined: Dec 2006
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2wd to 4wd conversion
hello, have not posted in a while, just finishing up the conversion on my 94 crew cab w/factory turbo i.d.i., bought a f250 rolling chassis w/banks turbo etc. we used a trammel gauge from a body shop, measured and cut both frames just in front of trans. crossmember, unbolted cab and front clip, rolled out 2wd, motor and trans. rolled in 4wd motor, trans, and transfer case, welded, boxed, and diamond gusseted splice, shortened original rear driveshaft, front shaft length was fine, cut hole for transfercase shifter, both trucks were e4od only thing left is remove TTB, add 1 leaf spring to front and dana 60 ( will probably have to shorten front shaft at that time) total working time so far has been about 30 hours, also want to say thanks for all the great tips and advice this is THE site for all the i.d.i. owners.
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Lead Driver
Joined: Nov 2003
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From: Campbell River, B.C.
Originally Posted by oldfords4u
hello, have not posted in a while, just finishing up the conversion on my 94 crew cab w/factory turbo i.d.i., bought a f250 rolling chassis w/banks turbo etc. we used a trammel gauge from a body shop, measured and cut both frames just in front of trans. crossmember, unbolted cab and front clip, rolled out 2wd, motor and trans. rolled in 4wd motor, trans, and transfer case, welded, boxed, and diamond gusseted splice, shortened original rear driveshaft, front shaft length was fine, cut hole for transfercase shifter, both trucks were e4od only thing left is remove TTB, add 1 leaf spring to front and dana 60 ( will probably have to shorten front shaft at that time) total working time so far has been about 30 hours, also want to say thanks for all the great tips and advice this is THE site for all the i.d.i. owners.
30 hours? not bad at all.....I don't suppose you have some pix of the conversion?
