Hey guys just thought I'd duck in and give you all an update on the 4x4 conversion of my 96 F150. The front axle/ suspension is all bolted in and fits like a glove! It took a bit longer than planned because I sent out all the suspension components to be sand blasted. I did have to drill three 1/2" holes because I installed a 2.5" suspension lift along with converting the truck to 4wd. Other than that if it would have been a stock 4wd conversion it would require zero drilling. I added a drain plug to the front diff housing and replaced all the seals for greater ease of maintenance. I am waiting on getting my tranny back from being rebuilt (ZF 5) and getting the correct ratio ring and pinion I need for the rear axle. It shouldn't be too much longer and she will be back on the road! I can hardly wait!

 

Please keep us updated. I'm planning the same operation on my 1990 as soon as I can find a suitable parts truck. Glad to see I'm not the only one who came up with a crazy project to tackle.

 

Yeah most of my buddies think I'm nuts for doing the conversion. Most people asked why not just sell this truck and buy a 4x4. Well I have several reasons behind my madness: The truck has low mileage for a 96 (130k), The body and frame are in pretty nice condition, I like the the truck it runs and drives like a dream, I like the challenge, and lastly to prove a point that Chevy isn't the only one with interchangeable parts! I tried to keep it as close to period correct as I could, the only thing that isn't is the front brakes. The axles came from an 88 Bronco, it had 3.55s with an LSD in the rear. The transfer case (BW1356) came from a 93 F150, the trans crossmember came from an 89 F250 4x4. What really made me decide to go ahead with the conversion was when I broke the original light duty M5OD in this truck. I located a used ZF 5 speed online, which is what I really wanted to have in there anyway because of the better gearing and heavy duty design. It came out of a 4x4 F250 so it had the t-case adapter housing on it already, and at the time it was the only ZF I could find. It bolted right in place of the M5OD however I did have to swap out the original trans crossmember for one out of a 4x4 to gain the needed clearance for the front driveshaft. I have been taking pictures of the project as I go, I plan to post them when the project is done.

 

How many hours do you have in this project so far?? It is good to know that this conversion is basically a bolt in project. I bet that you will love the ZF offroad!!!

 

I haven't really kept track of my total hours working on this. It's one of those things I pick away at it when I have time. Fortunately I am not out a daily driver, I have been driving my 84 F250 diesel which isn't too hard on fuel. I am really looking forward to having the 96 back on the road. It is a direct bolt in swap the TTB lift kit brackets (2.5") I used came off my 84 F150 4wd and bolted right (with minor drilling... required for the lift kit) up to my 96 F150 2wd chassis. The 4wd front axle/ suspension bolted right in place of the 2wd set up. The steering linkage is 100% interchangeable on all 80-96 1/2 ton pickups and Broncos... 2wd and 4wd. The rear will require installing a 2" lift block or add-a-leaf for the truck to sit up properly. I am going with a Rough Country 2.5" suspension lift (had it laying around) along with the 4wd conversion. I am going with an A.A.L. and a factory 2.5" lift block from a Ranger to reach the desired height. The trans crossmember bolts right into the same holes, (2wd or 4wd) the hole for the 4wd shifter was already cut out (had a cover plate on it) which made it really easy.
I actually have driven this truck with the ZF in it, I had the tranny and transfer case in the truck with the 2wd front end still under it. I had it in the woods a couple times and it was really nice having that deep (5.72) first gear for crawling and pulling trailers. You almost didn't notice the ridiculusly tall (2.73) rear end gear. It's a far cry from the M5OD that it originally had. It should be a good combination with the ZF, BW1356, 32s, 3.55 gears, and a locker in the rear... the 300 six has tons of torque so it should go almost anywhere I want off road. I guess if all else fails I'll dig out my Warn XD9000 "5wd"!