2-Wheel to 4-Wheel conversion, using D-50
 

Well this topic came up earlier about converting a 2-wheel drive to 4-wheel drive. I went ahead and lined up some pics of what I have going on, as I am converting my 1994 F-350 2-wheel drive to 4-wheel drive. The donor truck is a 1997 F-250.

For now, I will be using the D-50 IFS assembly, and later on switching to the D-60 or 70. In the mean time, here is what I have found as far as measurements that are needed, and necessary parts. The factory used slugs pressed and formed to hold the mounts to the frame. As I progress I will post more pics, but today was the first step. Here is what I have so far. Of course before removing any of the mounts or shackels, making sure the springs and axle is removed first..
http://i220.photobucket.com/albums/d...g?t=1272000189

http://i220.photobucket.com/albums/d...g?t=1272000331

http://i220.photobucket.com/albums/d...g?t=1272000380

http://i220.photobucket.com/albums/d...g?t=1272000451

http://i220.photobucket.com/albums/d...g?t=1272000512

Now here is what I have on the 2-wheel drive..
http://i220.photobucket.com/albums/d...g?t=1272000570

http://i220.photobucket.com/albums/d...g?t=1272000622

I will have more as I go..

Changing over the suspension is the most time consuming part. Once that's done, the rest is pretty easy. I cut off the front mounts and welded them into my 2wd frame.

This is helpful. I hope to be getting my parts truck soon (If the guy will sell it) so I can do this. And its frame it a we bit diffrent, it has for the front most shackle, it has a shackle that looks like its a mini version of the front hanger on the rear. Its diffrent. But hope to get my parts truck so I can help you out (Hopefully) but good pictures, thank you a million for the drawing in them, it helps me alot =)

What I was most concerned about what the K-Member on the chassis. I was not sure the measurements were the same, or if the D-50 would bolt up. Even though it will be going bye-bye after I get my hands on a solid axle.

There are two brackets that hold the differential to the K-member, and the mounts can be unbolted from the cross member. But new bolt holes will need to be drilled out for the 2-wheel drive cross member. Thats about the biggest challenge I see.

What I found even more interesting, is the steering linkage. Its the same between the 2-wheel and 4-wheel drive systems. I am going ahead and using the gear box from the 4-wheel drive, as it has better turning radius then my 2-wheel drive.. I get tired of completing 10-point turns in the drive-thru's! LOL!

Good stuff. I'm going to be doing this next year.

One of the local bus services that transport handicapped people have an E 350 van.

The outfit that did the conversion was Quigley up in Pa somewhere.

I hope to get a closer look and crawl under it one day, but they used a Dana 60 with what looks like a short four link with coil springs to give it 4x4 for winter travel here.

Probably only raised the front bumper a couple inches, and from the side it almost looks like a stock van.

Quigley does good work. They've built up quite a rep. Dually, the mounts for the D50 I-beams should be the same as the ones for the 2wd. I'm not positive on that one though. Brownie, are you actually going to go ahead with it? I hope so.
Also, awesome pics Dually. They will be VERY helpful to any that are thinking of doing this conversion in the future.

Yep, as soon as I move back to Oregon the 4x4 swap and ZF5 swap are going into my 'Stroke.

You're doing the tranny swap too? Cool. Are you using the '88 in your sig, or do you have another parts truck?

I'll be using the '88.

The trans and t-case will bolt up to the PSD motor, just need a '95 clutch and flywheel. Then all the front suspension will be going on mine. Only bad part is before I bought the '88 someone had swapped the Dana 60 out for a D50 TTB front axle. So I'll be running the TTB up front for a while till I can buy a Dana 60 for it.

Just get a new clutch and SM flywheel from Valair. When I swapped, it was cheaper to change it all than to just getting the clutch and pressure plate for the DM flywheel. The feel is way better too.

That's what I was planning. SMF and a good clutch from Valair.

Glad to hear it. Hey, Dually, any more progress??

The pivot points on the D50 and TIB front ends are not the same. The D50 axle is straight, with the pivots vertically in line with the center line of the axle. The TIBs come off the knuckles right at an angle and then hook upwards at the ends even more. The TIBs are also longer, with quite a bit more overlap.

Both of these trucks are stock:

https://i1008.photobucket.com/albums...g?t=1272296362

https://i1008.photobucket.com/albums...g?t=1272296354

Note how the D50 axle pivot is under the corner of the cross member and down about 2". Compare that to the TIB that is past the end of the cross member towards the opposite tire AND is also tucked up higher.

This shot gives you an idea how much the beam is out of line with center:

https://i1008.photobucket.com/albums...g?t=1272296723

The D50 is "square" to the center line of the tire instead of making a "X" at the middle.

My mistake. I didn't realize you had the solid D50. I assumed you had the TTB D50.