WillGCT

Alright, in about a month I'm going to start converting my 96 2wd into a 4x4. It's a regular cab long box 5.0 4r70w auto 3.55. I have found a 94 4x4 that is the same motor, transmission, cab and bed configuration. I also found a 3.55 D44 TTB as the donor has 3.31 gears and I like the 3.55 gears. I also found a manual shift BW1356 and shifter as the donor was a push button 4x4 and I want a manual shift transfer case and hubs. The rolling parts chassis will be donating the transmission, driveshafts, coil buckets, coils, shocks, and other misc parts.

My questions are as follows:

1. What in all from the front do I need to take off the 4x4 donor in terms of the suspension and steering componenents?

2. My truck has dual tanks, will that be an issue?

3. Do I need to modify the exhaust at all?

4. Any suggestions from guys who have done this before?

BLDTruth

1) Tie rods I believe are the same but the pitman arm is different. You've listed the rest I think - springs and buckets, shocks, axle, transmission, transfer case, driveshafts. I think brake lines are longer on a 4x4. Also check on the axle/I-beam pivot bracket. While you have that "new" dana 44 out of the truck, it would be a very good time to rebuild it disc to disc. They are a real pain to work on while on the truck.
2) Shouldn't be since it is a long bed.
3) Shouldn't need to if it is stock.
4) My first piece of advice to anyone doing this is - Just buy a 4WD truck and sell yours. By the time you are done doing this, you will either be completely thrilled or completely pissed off that you didn't just buy a 4WD truck and be done with it. It depends on how much you love your current truck, or how attached you are to it sentimentally.

Something else to consider - you will need a 4x4 computer for a 96 with your tranny, engine, and manual shifter combination, which means anything you add electronically will need to be compatible with a 96 and OBD2. You don't HAVE to have it but if you want to see the 4x4 light on your dash when you shift in to 4WD then you will need it.

WillGCT

Thanks man. I plan on keeping this truck for a while longer and I already have way too much into it with the new radiator support, etc. Not having the 4x4 light on the dash isn't a worry at all. I did some research and the 4r70w was the same from 92-97 so that isn't an issue. My exhaust is stock with the exception of a Flowmaster dual cat back system. Did some looking on Rock Auto, LMC and others and the radius arm brackets, coil buckets, etc with the exception of the driver axle pivot bracket are the same as 2wd, as are the calipers, pads, and brake hoses in the front.

WillGCT

Did some more reading and looking using LMC, NPD, and JBG, and OEM Ford Parts lookup that the pitman arm between the 2wd and 4x4 are the same. I will obviously measure them when I get the parts truck. I am going to check over the axle as well and replace parts as needed. It will be getting manual hubs if they are auto.

BLDTruth

Rockauto listed 2WD and 4WD versions of the pitman:

https://www.rockauto.com/en/catalog/...itman+arm,7368

You're right on the brake hoses its the rear that is different between the two.

Chris_1

iTrader: (1)

Most of the pitman arms I've pulled off 4x4's have a drop to them. Because the truck sits higher.

WillGCT

Thanks guys. I'm leaving the rear suspension alone and will just swap the pitman arms between the 2 trucks.

ngraham2010

When I swapped mine over there was no difference in pitman arm drops. I ran the "2wd" one for close to a year before putting a drop arm on when I lifted it 6 inches.

WillGCT

Awesome info. Do any of you guys know if the axle pivot brackets are different between the twin I beam front end and the TTB?

Chris_1

iTrader: (1)

I haven't seen any difference. Pretty sure they're a bolt up.