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Question for those who have done 4wd conversion...

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Old 08-20-2010, 10:54 PM
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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.
Old 08-20-2010, 11:40 PM
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Originally Posted by stang68inftc
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.

Originally Posted by stang68inftc
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.

Originally Posted by stang68inftc
Do I need a transmission crossmember?
Most likely.
Old 08-21-2010, 01:03 AM
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Originally Posted by Just call me Sean
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
Old 08-21-2010, 06:21 AM
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We'd do it

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Yep, the transmission has to come completely apart. Plus that crap is used.
Old 08-21-2010, 10:58 AM
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Originally Posted by Just call me Sean
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.
Old 08-21-2010, 12:09 PM
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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.
Old 08-21-2010, 08:26 PM
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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?
Old 08-21-2010, 10:19 PM
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Yep, it will work.



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