2wd-to-4wd conversion
 

so im looking at options for my truck. i want/need 4x4. how hard is it to convert a 4x2 to a 4x4. anyone have experience/advice. will i need a donor truck or just new axle / other parts. thanks. trucks in my sig.vvv

1) Sell 4x2
2) Buy 4x4

This conversion is easier than anyone ever makes it out to be. Its actually REALLY easy. Buy a front axle (it bolts into place of the 2wd stuff). Buy a 4x4 trans/tcase. And install! Driveshafts should be easy to find at the junkyard, because you have a longbed. Before you start buying stuff though, consider anything you may want to eventually do to the truck.

For example, if you want to lift your truck, install the front axle the same day you do the lift kit. You have to completely remove the front end anyhow when you do the lift.

When you buy a transfer case case, consider getting your tcase from a Bronco instead of an f-150. All Bronco tcases are fixed yoke.

I'm not sure if you have a 5 speed or an auto, but if you have a 5-speed, try to find a zf-5 from an f250/350, instead of the m5od-r2 out of a F150. Better 1st gear, stronger trans, and still has O/D.

And since there are always people who think I'm talkin' out my ass when I say how easy it is.... here is my truck... started as a 2wd, is now a 4x4. Hopefully soon will be 8-lug with 4.10s and a sterling 10.25" rear.

Attachment 506650
http://saoffroad.com/forums/picture....pictureid=7773

2wd to 4wd conversion
 

hey man i got and 88 version truck like urs and i have the 300 straight 6 and i want to convert mine to 4wd can u send me some pictures and explain to me in more detail i would really appricate it

I just did mine too and I did a 6in. lift at the same time, I picked up a dana 44 TTB front end complete from disc to disc, its a unique one (little did I know) Ford only made this version from the very end of 1987 to the very beginging of 1989. Where the hub assembly is one peice and pulls off with the wheel. I was trying to find bearings/parts for it and I didn't know what year it was from and I had one hell of a time. BUT anyways just know your #'s on your axles (year and ratio) you need to match your front and rear gears. And if you want to do a lift, do it now! it took me and two other guys to roll it under the truck and set up to mount it..... but total cost was $500

Soon after my rear end went out (had 3.70's in it) so I picked up a fully built ford 8.8 and I know its not the 9 inch but I wanted a direct plug in/bolt up with no problems plus I got this one with 4.10's and a detroit locker with the papers for warranty:D for $150

I'm looking for a zf-5 speed right now w/ a 205 t-case right now to finish up and do it right.

hey man i got a 92 ford 302 aod 2wd. im looking to do this swap as well as swap a 351w in it at the same time. i was planning on buying a donor truck (89 f150 4.9 5 spd 4x4) i already have the motor plannin on just puttin cam lifters roller rocker arms heads intake carb and headers on it and drop it in. my question is will the 5 speed from the f150 hold up to the power of a moderately built 351w? any advice is appreciated thanks.
-ryan

I am converting a 88 bronco to 2wd and will have all the parts you need but I am in Ohio.

why would you do that?

go for it if you are willing to do the work

It is no harder than changing ball joints , piviot bushings or radius arm bushings.

Seems like everyone that has no clue how to work on a truck theirselfs make it out to be this long hard process to swap it out.

It is 4 nuts and 6 bolts that hold the whole front axle on. 2 radius arm nuts 2 bolts and 2 nuts holding the axles at the pivot on the cross member and the 2 bolts holding the springs to the spring towers.

now how hard could it be to take that apart?

this swap is a bit harder because you have to swap stuff under the dash for the clutch, and steering column and you the dash stuff from the 89 donor truck will not work under the dash of a 92. sorry:blush:
but the axle and the trans off that 89 will work.

and the reason this swap is worth it. is because 4x4 trucks are normally used as trucks and 2wd trucks lived a easy life.
that in turn means the bodies on the 2x4 trucks are nice with less rust and dents. and when a 4x4 has lived its life and is no longer on the road. parts get cheap on them. as the ttb goes for about 150 bucks.

U also have to change the trans and ad a transfer case a wrecked or blown up truck would be perfect so you have all of the. Parts that you need

Do you have an automatic or manual transmission? If its auto like mine is, then i think your doomed like me. There are no automatic 4x4 transmissions for the 6 cylinder, only manual (which means you would also have to convert to a manual transmission) and i dont think that you can bolt up a 302 transmission to a 300.

can anyone confirm that what im saying is correct, or can you do this tranny swap?

Im also looking to do a 4x4 conversion and was hoping somebody could give me a parts list and from what year truck that would need to be off of and also what year and model would you find a Zf5 trans.and if you had two guys working on it about how long would it take you? thanks guys

P.S. i have a 1989 F150 302 longbed manual transmission with f250 coil springs in the front.

i beleve that you can find the zf in the f150 from 88-96

I thought they were in the f250 and f350 models. I could be wrong though. But can anyone just give a list of all parts needed to be swapped and what years they need to come off of?

Ya they are but they were in them from 88 untell 97 and u will need the front end drive shaft t case trans t case shift lincage and shifter and that's about it

yeah your completely wrong.

no autos for the 300???? where did you ever hear such a thing.

our trucks have 2 trans bolt patterns small block(300,302,351,) and big block (460 and diesel)
as long as you have a small block bell housing you can put a 300 infront of it.
the trans i have in my 95 is out of a 79 f350 that had a 351 infront of it.

If you had two guys working on this could you get it done in a weekend (Friday, Saturday , Sunday)?

the right guy and the right tools, it can be done in one day.

when i rebuilt my ttb (everything new; u-joints, third member gaskets and seals, ball joints, tie rods, rotors, new hub bearing and races, hub seals. i did that by myself in less than one day.

but like i said the right guy and the right tools and it is easy.

thats if your staying with the same style trans( auto to auto or manual to manual, and it is also easier if you swap with stuff right about the same year.

Thanks for the information

Hey I messaged a guy on here who said he went to a junkyard and got all his parts and didnt use a donor truck and I don't have much experience with junk yards and I was wondering if I walked in with a list of parts can they locate and get them for me or are all junkyards like pull-apart? Thanks

No what im saying that the only 4x4 300 has a manual tranny. there arent any 4x4 300s with automatic ones. If there is, then that is a HUGE suprise, because no junkyard has an auto 4x4 300 tranny, and every 4.9L 300 4x4 truck that ive seen has a manual.

However the news about being able to bolt up a 302 tranny to a 300 engine gives me much more hope for doing a swap someday:blush:

you should be able to walk in with the list and they will get you the parts

Depends on where you go. If you want them to pull everything so you can just pick it up at the door it's going to cost you more. Pull it yourself and it's cheaper, real cheap if you go to the right place on the right day. I swapped out my 4 speed for a 5 speed and got everything including transmission for $90.

That's what I hope to do to swap my 3 speed ( four speed with a granny gear) for a 5 speed and with a little help from someone up above it'll be a Zf5

Good luck with that. I grabbed the best looking M5OD from the newest truck I could get one from ('96) and it works great. I did wear out the 1-2 shift fork and the shifter bushings are gone but those are easily fixed.

i have two more questions. 1 what year/models have the Zf5 trans. that would bolt right up to my truck and i was told that a front ttb axle from any year will work is that true? thanks

Also I priced all the parts needed for the conversion from my local junkyard and the total was $476. Does that seem about right ?

damn thats cheap :eek:

They got some good deals but I have to pull off the all the parts. Pain in the @$$

Not as cheap as I could get it but decent price with warranty.

Anyone know?

Very rare to find an F150 with the ZF, you'll have to look at 250s with the 4.9, 5.0 or 5.8. I think they started in '88. Axle '80-'96.

Thanks Sean you've been tons of help :thumbsup:

X2 on that. but i would look for a 92 or newer axle. if you can find one with the 6 bolt outter lock hubs they are better. STAY away from the 86-88 or 89 axles the outter locks are junk and a pain.

What model/years would have the 6 bolt outter lock hubs

i'm not real sure on that, frmo the years i've had and reading on here it was kinda like whatever ford got in the mail that day went on the truck.

i know guys with 95's that had 3 bolts but my 92 had 6 bolts, my 86 had 6 bolts but my bros 85 and my dads 84 both had 3 bolts.

according to warn hubs site
87- and early 88 WARN makes no hubs to fit, they have a flange mount hub.

and if the truck had 3 bolt mounting you have to order a special kit from them.

and they said about the fulltime 4x4 hubs but i've never seen one of those on a ford.

Oh yeah, '87-'89 axles are harder to find parts for from what everyone else says.

You should look for straight axels. I hate the twin I beam front end fords been using for ever

i agree with the strait axle swap but they are not a bolt in operation and the only a limited number of years that had the strait axle that would be a good swap and lots of the older trucks have made their way to the crusher. but the ttb was under all the trucks for almost 20 years. so parts are still plenty.

True the parts are a plenty but if you put a pair of bulletproof Ford 9 inch axels in you no longer need parts

ford never made a 9" frontaxle,

Now I'm all confused I just want to swap the axle with another ford 4x4 axle what do I need from warn shouldn't they just bolt on?

???

To keep it easy for you just use stock parts that we listed.

Sounds good

You might just want to take a look at this one. This may give me some hope as well.

http://www.autotrader.com/fyc/vdp.js...standard=false

I have a 81 F150 I want to convert...can I keep the same tranny but add a transfer case and if so, what would I need to do that?

I have a 1989 f150 that is a 4wd. It has a c6 tranny. And then I have a 1995 f150 with a 302 and 5 speed. They are both short bed regular cabs. Could I take the tranny and t-case out of the 89 and put it in the 95 and make it an auto since the c6 isn't a electric controlled tranny. And just put a floor shifter on the 95

I know I will need too buy a new flex plate since I can't use the flywheel cuz its off of a 4.9 and I will need too run tranny cooler lines to the radaitor. Is there anything else I'm missing?

My conversion
 

Lots of good info in these threads... Thanks to everyone who added good info. The article http://www.ford-trucks.com/article/i..._F100150s.html
also helped a ton.

I have a 1996 f150 ext cab short box 2wd 5.0 that is at the end of becoming a 4wd. I bought a dead 1995 f150 ext cab short box 4wd 5.8 (aka Project Donor) that was all stock. The switch was pretty straight forward and easy to do. It just took time, patience, and a wife to tell me to stop trying to make more improvements and modifications...

The front ends bolt right up. Big thing to check is make sure the gear ratio in the 4x4 front end is the same as the rear or you will blow a trans. Gears for both trucks were the same so I didn't have to touch the rear axle at all during the switch.

I was able to do the front end in a weekend after I got new bushings for the radius arms and axle pivots (Rock Auto.com). I installed a 4 inch Pro Comp lift at the same time so I had to change out the springs and axle cross members. It all bolts right up and I welded it to the frame cross for extra strength.

The hardest (and most expensive) part was the trans. Both trucks had a e4od so I had the 4wd e4od rebuilt with a transgo shift kit and a billet triple disc converter. It depends on what you have but this was easier for me to do rather than having to change out the tail shaft and install an adapter for the t-case. The 4wd trans already had the t-case in place but had 216,000+ on it so it was worth it to rebuild while it was out. Plus I don't have to worry about it later on and the rebuilt e4od will probably outlast the truck now. Do your research and find a good shop with experienced mechanics who are knowledgeable about what you have and explain what you want done. Pay attention to the small details and make sure you stay informed of what they find and what they do! Once the rebuild was done, it bolted right up. Same bell housing for the 95 (5.8) to the 96 (5.0). I changed out the rear drive line and connected the front. All of the cross members and supports bolted right up as well.

Instead of cutting a small hole in the floor board for the shifter, I took the high hump out of the donor truck and spot welded it to the 96 (2wd had a low hump). It was pretty easy, just pull the seats and roll the carpet back. I laid the plate down as a template (duh) and drew it out. Plasma cutter was the fastest and cleanest way to cut it out. Put the high hump plate in and rolled the carpet back over it with a newly cut hole for the shifter. Carpet stretched so I didn't need to replace it and the small gap up by the firewall doesn't bother me.

After the lift in the front and instead of stupid looking blocks, I did a shackle flip. That was super easy too and only took the better part of a day. Take off the tires and block the frame up high on some jack stands and put a jack under the diff. Unbolt the stock shackle, loosen the U-bolts from the axle and leaf springs, and drop the axle slowly to release the tension. Pull the bolts and remove the stock shackle mounts. I ground them off because I didn't want to pull the rear fuel tank so I could use a torch and didn't want the noise of an air chisel. Ground off the 4 rivots on each side and cleaned up the frame. Flip kit I used was from Sky's Off Road and came powder coated. Used grade 8 bolts and crimp nuts to secure it to the frame instead of the grade 5 bolts and nylon nuts supplied. I also ground off the powder coating on the sides of the brackets and ran a bead on the front and back to the frame for strength. Bolt the shackle back in and put it back together.

Last step was install of an auburn limited slip in the rear and warn manual hubs up front. Allignment shop was a must after all this, just to check my tape measure allignment in the driveway. Pinon angle was off in the rear because of the shackle flip and new drive line. I put in 4 degree shims and it lined right up. It's at about 3 degrees now and is as straight as I can get it. No noise or vibrations when driving or clunking in reverse. Truck pulls great and does everything I need it to. Whole thing took a couple months because of (money for) the trans, time for rebuild, parts delivery, and personal schedule issues. All in all worth the effort to do, rather build one I can work on then buy one I have to pay someone to do it for me...

Hope this helps someone out there,

Cheers

Hate revive this from the dead, I'm new to Ford's (4wd trks, and this forum, hello to all) and will be acquiring a 90 F150 ext cab, long wheel base from my grandfather. I've been doing some reading on this an am pleased to hear it's a bolt on swap. ( a friend said I had to do a lot of frame reinforcing, n e ways) my questions are these: 1. Instead of having my transmission rebuilt, can I just swap it with one from a 4wd truck? 2. Is there a list any where, so I can start buying parts? ( a detailed one would be great) 3. I read, this raises the front a couple inches, what needs to be done to the rear? Any help (websites, links, etc) will do, if need be u can pm me,

No prob. This is what were here for.

U wont find an exact list, but check this out and let us know if there are any other questions. There are tons of us ready to help.

http://www.ford-trucks.com/article/i..._F100150s.html

Double post

Thanks, I have it booked marked. I won't get the truck until the week of Christmas. But I definetly will be needing advice, Thanks.

NP, start a thread on the swap and paste a link here. :D

Post a link to where?

If u decide to start a thread on your progress throughout the swap, Then post a link here so we can follow it.

Sorry, had a blonde moment, gotcha

I've got an 89 f150 with the 302 if I was going to do that I've got all of it down about what I need and how to do it but my question is what about the wiring wouldn't I have to change wiring harness out I've got an auto tranny and would want an auto 4x4 because I don't really feel like having to add clutch slave master cylinder and all

I guess it would depend on what trans you decided to put in. I put in another E4od with the t-case hooked up to it. My 96 (now 4wd) wiring harness doesn't have the plug that goes to my t-case to turn on the 4wd light on the dash so I just shift it manually when in 4wd. So basically if your "new trans" plugs into the same cylinoid pack then it shouldn't be a problem.

'89 wouldn't have an electronic automatic.

Is it possible to have an auto tranny with standard transfer case?

Yes.

If I gather all this correctly, 1. my best bet is to get a donor truck. Now can I use a 90' 4x4, reg cab short bed, or a ext.cab short bed as a donor to a ext cab long bed trk? 2. Rebuild the donor front end before even beginning the swap?

I would rather do it part by part, I believe it would be cheaper vs. Hunting down an exact donor truck , as I've read that several on here have done this swap for right around 500 or less for parts. BUT, I can't find an exact part list so I can start shopping.

Damn... Lol I made this thread a looong time ago :laughing:

quick swap parts list.

front axle assembly( this includes the TTB axle, the radius arms, the coils, shocks. tie rods, drag links, pitman arm,
front drive shaft
4x4 transmission(easiest way is to find the same trans you have ie: e4od 4x2, get an e4od 4x4 trans)
transmission to transfer case adapter
transfer case
transmission cross member out of a 4x4 truck.
rear drive shaft (best to find the same setup your truck is ie: reg cab long bed, get a 4x4 rear shaft out of a reg cab long bed.)
transfer case shifter assembley
plastic transfer case shifter cover(thing on the floor inside the cab)

the easy way to do the swap is to exchange your trans for the 4x4 model of the same trans you are already running.

I know my truck had the transfer case switch wiring, for the 4x4 light on the dash, there on the frame rail, ( it was a 4x2 when i started my build)

if you want the rear suspension out of a 4x4 with the 3" springs and not the 4x2's 2.5" springs you will need the
springs
spring top plates
shackles
shackle hangers( the brackets that are riveted to the frame.)

Ftmfw! Thanks a bunch, time to go grocery shopping!

Won't the 4x4 transmission have transfer case and adapter on it?

more than likely, you'll find the Assembly together, but since they are separate parts and you can buy them apart, i listed them separately.

Thanks again

Is it this easy to do on post 1996 trucks?

You might want to ask that in the post '96 section.

I did a few months ago but all I got was the burn/sell your truck and buy a 4x4 answer.

Yeah, they're a bunch of dicks over there. :D

I would think it depends on the year. The wishbone suspension on newer trucks would be more tricky to transfer and I'm not sure you can do anything easily with the torsion bar setup. Then there is the computer question. You may have to change that and deal with ABS systems and electronic transmission. Not to say it can't be done, but I'm guessing its a bit more complicated than the old trucks.

I'm not sure I don't have the tranny or transfer case anymore but I have everything else on my parts truck. It looks like it would be fairly simple as long as the frames aren't different.

I was thinking about this swap at work and have read on more than one forum/thread, that this could be done for close to $500, how!? The transmission would cost that much alone.

I paid $50 for my transmission. It all depends on where you shop.

Yeah if you shop long enough you can find the stuff cheap. I traded my 4x4 tranny to my friend for his old one and a set of wheels and tires for my trailer. (full set of s10 wheels) sadly the old tranny was stolen from me before I carried it inside.

you can pickup complete TTB axles around here on scrap trucks for 150 bucks. 250 bucks with lift parts.

I got lucky and found all the swap parts for $300. Then, dude that I got the parts from called me before I even got them installed and told me he found receipts inside the truck for lockers and 31 spline axles installed in the front and rear. I've yet to throw anything at this truck it cant handle.
I also did each component one at a time. I did the front axle first (4x4 poser :p) then i did the rear axle about 3 weeks later. Then maybe a month later I did the trans/transfer case.

Where are u at, I'm in e.tx, all the junk yards are about 1 1/2 away.

Hey ya'll. first post here and thought I'd revive this old thread.

I have an 95 F150 extended cab long bed 2x4, 5.8 with an A4OD and am looking to do this conversion. I understand all the mechanics involved but am more interested in the parts interchangeability. I am looking at a 1983 Bronco as a donor. The body is trashed but all of the running gear is there. Would this make a good donor vehicle or should I look for something from the 90's? I guess, my main concern would be the front axle hubs and brakes.

The front end will work for you but you'll need a 4x4 e4od tranny. Best way is find a truck with the same tranny as yours and you can swap the front end tranny and transfer case all at once.

I've got my own donor truck same year and same engine but 4x4, I could swap it simple right? But would I have to cut a hole for the boot and shifter? 95 302 4x4 swap into 95 302 2wd.

Yes.

X2

My next issue is time. The 4x2 is my daily driver and I work all week until Sunday. I've got too big of dreams for a 19 yr old.

What's wrong with the 4x4 donor truck?

Hell no you don't I'm 18 and I'm trying to do the same thing, Ive got a junked out body 4x4 I wanna buy a motor and build it all onto the frame and Athens swap the cab, bed and exc

The bed is shot, the interior is golden. Cab is golden as well. Issues to get rid of truck and take what I can is that I'm moving and parents need space. I bought it for cheap as a play truck and lost time to fix.

Might be easier and faster if only problem is bed to change the bed on 4x4 truck.

2wd to 4wd using 96 Bronco
 

So I got this 1996 Ford Bronco for $500. It has a busted 5.0 but 4x4 components work. It has manual hubs, manual transfer case shift, E4OD auto trans. I want to convert my 1995 F150 extended cab short bed into 4x4 using the Bronco parts. It has 4.9L I6, E4OD trans, and gear ratio of 3:08. The only issue I see is the rear driveshaft, I assume it will be too small. Any flaw in my theory? What size driveshaft will I have to get?

Better check on the electronics for the trans. 95 is OBD1, 96 is OBD2. Might not matter, but then it just might too.

1989 F150 2wd to 4wd conversion
 

im looking to rip my 4x4 out and trade for a 2x4. Theres quite a bit more to it than just transmission swap and bolt up. Im willing to trade someone even. Mine is an e4od with about 180k on it, locking hubs, pb 4x4. If you or anyone else are interested pm me.