New to this forum site been using it for years for advice on working on my truck and love the collaboration on here from other members. I currently own a 2wd 2006 f-150 regular cab long bed heavy duty payload package. The truck currently has 112k miles and I have done a number of upgrades to "make it mine". In the last year I have bought bfg ko2 tires for the truck and it has performed surprisingly well in the snow, but I am looking into the 4wd conversion. Now all of the forums I have read on this all advise the same thing "sell the 2wd and buy a 4wd." However all of these forums talk of an electric shift 4wd conversion whereas my truck would be ideal with the factory manual 4wd that is often in the xl models. This also seems like it would be easier than the electronic shift. The truck has a lot of sentimental value for me and I love the fact it already has the heavy duty axles as I am looking to put a big lift on the truck if this can be completed. If I seem to have overlooked anything please join in collaborating. I do not need a lecture on selling my truck for a 4wd truck I do not need to do this conversion by any means just looking into it. This project can also be cost effective for me as I have a variety of pick n pulls in my area that have the parts I will need for very cheap.Here is a run down of everything I have found I need or will need to do for the conversion:
-4wd driveshaft (correct size based on configuration of my truck)
-manual transfer case
-4wd shift lever assembly
-shifter linkage
-4wd transmission (or modify my current transmission by changing rear output shaft and tail shaft housing)
-carrier axle 4.10 gear ratio (got lucky and spotted one of these at the local pick n pull!)
-new cv axles
-locking hub actuators
-4wd struts (need to replace my current struts anyways)
-IWE Solenoid and lines to lock hubs
-haven't had chance to compare 2wd and 4wd frames but may need cross members mounted and such to mount these parts
-must figure out connections for PCM and gauge cluster

 

UPDATE: examined some 4wd and 2wd frames at junkyard today and found the frames look to be the same with the exception of the cross members on the 4wds. The cross members bolt in to existing brackets in the 2wd frame so no welding of brackets to the frame would be needed. A relief to know wouldn't have to chop up frame or anything just 4 bolts or so.

 

that's good news!