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Old 08-20-2010, 10:54 PM   #1
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Default Question for those who have done 4wd conversion...

Hey guys, I have a 96 f150 2wd 351 e40d long bed extended cab, I am planning to convert it to 4wd in the near future and have began gathering parts. I have the front axle out of a 91 Bronco with 3.55 gears, a 8.8 out of a 92 f150 with 3.55 gears, a borg warner 1356 transfer case that was in a bronco (not sure it was originally from the bronco though).

Things I know I need but could use some direction on:
-Either a e40d from a 4x4 or a convert mine to bolt to the transfer case. I have found a kit on ebay that has all the parts needed to convert my e4od to a 4x4 e4od for 110 shipped.
-Drive Shafts
-Shifter assembly
-Lock Out Hubs

Is there anything I am forgetting?

Also, will my brakes on the 2wd front axle transfer over for use on the 4wd axle? I have the discs from the 4wd axle, but I'm not sure they're usable, they're very rusty. I do not have the calipers from the 4wd axle.

I plan to replace parts that I should before finishing the conversion, these include:
-Ball Joints
-Bushings
-Discs, Pads, Drums, Shoes
-U-Joints

Do I need a transmission crossmember?

Also, I plan on doing this in as many as 3 stages to keep the truck drivable. One or both axles at the same time, then later on then transmission and transfer case.

Im looking for thoughts, suggestions, things I haven't thought about yet, advice, etc. Let me know what you think.

Last edited by stang68inftc; 08-21-2010 at 11:00 AM.
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Old 08-20-2010, 11:40 PM   #2
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Quote:
Originally Posted by stang68inftc View Post
Things I know I need but could use some direction on:
-Either a e40d from a 4x4 or a convert mine to bolt to the transfer case. I have found a kit on ebay that has all the parts needed to convert my e4od to a 4x4 e4od for 110 shipped.
Do you have a link for this? If it comes with the tailshaft then complete transmission disassembly is required to change it. I'm pretty sure the tailshaft length is different from 2wd and 4wd.

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Also, will my brakes on the 2wd front axle transfer over for use on the 4wd axle? I have the discs from the 4wd axle, but I'm not sure they're usable, they're very rusty. I do not have the calipers from the 4wd axle.
I don't know if the calipers are the same, but the rotors sure aren't.

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Do I need a transmission crossmember?
Most likely.
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Old 08-21-2010, 01:03 AM   #3
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Originally Posted by Just call me Sean View Post
Do you have a link for this? If it comes with the tailshaft then complete transmission disassembly is required to change it. I'm pretty sure the tailshaft length is different from 2wd and 4wd.

I don't know if the calipers are the same, but the rotors sure aren't.

Most likely.

http://cgi.ebay.com/ebaymotors/FORD-...Q5fAccessories
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Old 08-21-2010, 06:21 AM   #4
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Yep, the transmission has to come completely apart. Plus that crap is used.
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Old 08-21-2010, 10:58 AM   #5
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Yep, the transmission has to come completely apart. Plus that crap is used.
I can't imagine that shaft or the adapter housing are parts thar really go bad are they? Are you saying that would be a bad choice to make for getting the tranny where it needs to be? Do you think I would be better off getting a used 4x4 tranny to swap in, or getting a shot 4x4 tranny to take the parts off of (really the same as the ebay kit plus I have to disassemble 2 tranny's), or buy a reman 4x4 tranny (never know what kind of quality you are getting with those from what I have heard)?

Also, another part I added that I forgot to list was lock out hubs.
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Old 08-21-2010, 12:09 PM   #6
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Do you know how to rebuild an automatic? That's what you'll be doing if you buy that kit, so you might as well buy a rebuild kit too. That shaft is probably like $30 brand new, and you could get the transfer case adapter from a junkyard pretty cheap. If it were me, I'd buy a used 4wd tranny to swap in.
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Old 08-21-2010, 08:26 PM   #7
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I found a auto trans out of a 97 4x4 f250 with a 351 and 108k miles for 200 bucks. I am assuming a 250 transmission behind a 351 would be the same e4od I'm looking for right?
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Old 08-21-2010, 10:19 PM   #8
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Yep, it will work.
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Old 08-21-2010, 10:19 PM
 
 
 
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