02 2wd to 4wd conversion

[WolfJ1]

I have a 2002 2wd explorer XLT it has been a great truck but my first that wasn't already a 4X4 . I have had a few explorers in the past that i have modified and want to convert this one to 4wd solid axle but want to maintain coilover suspension for greater flex and would also like to do coil over suspension in the rear for the same reason I do alot of welding and fabricatining in my shop and have done a simalar swap on a frie:navajo:nds nissan frontier and it worked great hes been wheeling it for a year with no problems but his was mostly a kit for the axle swap and already a 4X4 . I would like to use the dana 44 from an 80 jeep grand wagoneer up front and an 8.8 ford out back any suggestions or help would be great

 

[Limited02]

Well if you have the mechanical know how then you would be the first do to this if you do. What you mentioned can be done, just get creative. I would do it myself since I have everything, but then the ex is no longer a practicle DD and getting people in and out would suck, plus not parking in my garage would suck even more.

Also, welcome aboard

 

[Got2bneo]

give us some progress reports and take lots of notes, i'm sure there are some guys on here that would love to get their hands on that info.

 

[WolfJ1]

lot of reserch

I'm sure it's going to be quite a job but I will make plenty of notes and take lots of pictures I'm going to contact James Duff plus a local 4X4 shope to try to get some tips:exp:

 

[guitarfrk741]

I'm sure it's going to be quite a job but I will make plenty of notes and take lots of pictures I'm going to contact James Duff plus a local 4X4 shope to try to get some tips:exp:

Its not neccessarily going to be that difficult getting the axles mounted under there..especially if youre decent with fab work.The hard part is going to be the tranny and driveline angles.

You're at least going to have to get your tranny rebuilt with the 4x4 output shaft so a t-case can match up;and thats if you use a stock tcase.

Honestly, I'd find a different transmission that would work and has more t-case options.

As for the actual axles, a dana 44 is probably perfect for this app..just make sure the differential is dropped on the same side your tcase will be

As far as the ford 8.8 goes i can't really say anything,being that my SAS experience is limited to chevys and my ford experience is IRS

Also cant say much on the coilover setup..they tend to be a little more expensive than a leaf spring setup though and a leaf spring set up isnt too difficult

EDIT: definately going to be a big project..
but you should DEFINATELY do it..I need a reason to buy another 3rd gen

 

[WolfJ1]

reserch

Well I'm in the research stages now I put a call into James Duff they recomend axles from an early bronco (for width) and can help with parts that will work with some modification for the front 44 install and suggest a paralell 4 link for the 9 inch rear which is what i was thinking of now I just have to locate the axles , As for the tranny and T-case I'm still doing research I want to keep O.D. for better milage and drivability and would like to find a good t-case that is push button engage but durable enough for what I do with the truck which is trail ride not rock climb I don't want to hack up my interior and console to install a shifter.

 

[macknos94]

i think installing a 4wd shift selector could be done very clean. you could cut a slot in the center console and run the linkage through with a shift boot.

as for the tranny/ transfer case what about the one out of a 2001 body style f150 should bolt right up to the 4.6 or 4.0. i think it would be plenty strong enough and would allow you to use an electric switch for 4wd

 

[WolfJ1]

thanks

Thanks for the tips on tranny and T-case I'll check it out

 

[guitarfrk741]

Getting a pushbutton case to work is going to be VERY difficult with an sas If it's a case anything like the stock explorer tcase. Most transfer cases aren't just connected straight to a button.. They run through the ECM so when you push the 4 hi button.. It sends a signal to the ECM.. Then that goes to a 4x4 control module... Which then goes to the case..

To be honest a floor shifter would be ALOT easier .. Not to mention cheaper and more reliable(and can easily be made to look clean)


EDIT: but I'm not familiar with an f150 case.. It could be different since there's no auto 4x4 installed

 

[Bajadoggie]

i dont know if i can be of much help with the tips, not a fantastic mechanic but i would definitly like to see how your project goes. keep us updated!

 

[therealblinky]

i`ll sell you my 4x4 explorer for cheep. Save you some hassel

 

[WolfJ1]

thanks

thanks but for what i am doing i would still have to swap all the same parts the factory four wheel drive set up is to weak and not flexable enough to do any serious off roading at least the places that i go i have already broken to many stock drivetrains:exp:

 

[Hitchhikingmike]

Nice, I have thought about this before too. Can't wait to see what happens!

 

[PFC WHITE]

i am looking i to this as well!! i was wanting to know what i need to swap out and how much you guys think itll cost?

 

[Got2bneo]

i am looking i to this as well!! i was wanting to know what i need to swap out and how much you guys think itll cost?

Well on a PFC salary its gonna be a pain in the ass. lmao Control arms, transfer case, SAS(big money), lift(if necesary), ball joints?, etc. Its gonna put you out a good 4k atleast.
You artillery in fort steal? lol

 

[explorer99sport]

I was thinking of converting my 99 Sport 2WD to a solid front axle, but the Ford rear is good enough to get me through, keep us posted. If you need help let me know I know the guys from Low Country 4X4. Good Luck

 

[PFC WHITE]

Well on a PFC salary its gonna be a pain in the ass. lmao Control arms, transfer case, SAS(big money), lift(if necesary), ball joints?, etc. Its gonna put you out a good 4k atleast.
You artillery in fort steal? lol

lol no im a health care specialist however im on a medium sized (2 month)leave and getting free money right now thankss for your help 4k is much cheaper than my uncle told me (how ever much a brand new 4x4 is) how would i know if i need to lift first and do i do 4x4 lift or does it matter? can o just put bigger shocks for the coil over in the front and bigger shocks in the back? with out the whole 2k kit?

 

[Got2bneo]

lol no im a health care specialist however im on a medium sized (2 month)leave and getting free money right now thankss for your help 4k is much cheaper than my uncle told me (how ever much a brand new 4x4 is) how would i know if i need to lift first and do i do 4x4 lift or does it matter? can o just put bigger shocks for the coil over in the front and bigger shocks in the back? with out the whole 2k kit?

It depends on what you plan on using your 4WD for if you need the lift or not. Idk about the whole coilover suspension and if it works on the IFS/IRS.

 

[gueroo]

I have a 2002 2wd explorer XLT it has been a great truck but my first that wasn't already a 4X4 . I have had a few explorers in the past that i have modified and want to convert this one to 4wd solid axle but want to maintain coilover suspension for greater flex and would also like to do coil over suspension in the rear for the same reason I do alot of welding and fabricatining in my shop and have done a simalar swap on a frie:navajo:nds nissan frontier and it worked great hes been wheeling it for a year with no problems but his was mostly a kit for the axle swap and already a 4X4 . I would like to use the dana 44 from an 80 jeep grand wagoneer up front and an 8.8 ford out back any suggestions or help would be great

Were you able to do it? What did you use? I have a 02 explorer on 245 75 17 with a small 2in lift trying to convert it to a 4x4, I have my shop but haven’t gotten into looking for what I need for the 4x4

 

[410Fortune]

Well I’m not sure the op is coming back since this is from 2009

The gen iii explorer would take ALOT to be a solid axle rig front and back
First off you need a steering gear box instead of the rack/pinion
In the rear I believe the cv axles go through the frame, it maybe difficult to fit a solid axle
Under this frame and get a decent angle on the rear driveshaft as well as have a place in the frame for the axle to sit and still travel.
There are a few reasons why we have never seen a sas gen iii ( I know as soon as I hit post reply somebody will show me a gen iii sas explorer)