I have 1994 F150 regular cab long bed 2wd with 4.9L I6 and 5 speed manual. It has 189k miles which is not that bad for the I6 that engine from what i researched should last up to 300k if properly maintained.

I have done bunch of research and found out that 4wd conversion is pretty simple and can be done in one day of labor. I am an experienced mechanic so this looks really simple for me.

I have made list of parts needed;

- front half axles from 4wd f150
- transfer case
- front driveshaft
- rear driveshaft

There should be no wiring involved since transfer case is manual.

My question is what transfer case do i need which would bolt to my 5speed manual?

How do i find out what gears are in my rear axle?

Are there any parts i am missing?

I will already be replacing the worn font springs with Moog Cc884 springs which should level the truck.

This seems very inviting, because I paid $240 for the truck, 4wd parts can be had for around $500 give or take, plus all the parts I need to fix the truck up and make it reliable I could be around $1000 for 4wd truck...

What do you guys think?

 

You'll need a 4wd trans as well. easiest to find trans, transfer case together

 

Your case to mate up to 5spd would be a borg warner 1356 i believe. Rear axel id is on the door jam sticker or on the rear tag bolted to the diff cover.

 

Unless you also find a 5spd with a transfer case on it, you're 2wd 5spd won't work unless you change the output shaft as they are different lengths to bolt on the transfer case and you need the extension housing for the transfer case.

 

Way easier to buy a tranny and t case together, and get the trans crossmember its different for 4wd, has a dip for the front drive shaft.

 

And I'd count on a weekend to do it, If not more. Your bound to run into little snags along the way that'll take longer. Took me a 3 day weekend to swap 2wd auto to 4x4 5 speed, then an afternoon to swap the front axles although it didn't go quite as smooth as it could of.

 

Do you mind posting what parts did you use?

 

Just follow what everyone else is saying, my parts list was considerably longer because I went from auto to manual along with 4x4. I found buying a donor truck was cheapest in the long run, bought the wrecked truck for 500 took my parts then scrapped the rest.

A few things to look at are matching gears because they get expensive quick and make sure the tranny/transfer case come with the shifter linkage for the 4x4 selector (I didn't and now I can't find one). Also make sure you look over everything before starting the swap, I ended up having a leaky slave.

As for leveling the truck I ended up with about 5 inches, comparing the 2wd axle with worn out springs to the 4x4 with a leveling kit.

 

sounds like you got everything pretty much covered since you have a donor! At least with the gears, you would only have to buy 1, 2 at most! lol