officially looking into a 4WD conversion!

[LONO100]

Hey fellas, although it would be a lot less work if I sold my rig and bought a 4WD sport trac, I've decided that I am formally going to set a long term goal of attempting a 4WD conversion within the next year or two. Before you crack me for being a cook, let me explain my reasons:

First off, it isn't a matter of need, I already have two other vehicles (jeep wrangler JK and Subaru legacy) that have 4 wheel capabilities. I think it would be a great project to undertake, document, and accomplish. It would be great to document everything it takes to do one of these to let everyone know what's involved. Why would I do this instead of just buy a 4WD explorer? Well, first off, I decided, I don't want to buy another vehicle for at least the next 7 years, second, its not about the money, its about the learning experience. Well, its also about the money, but I feel that I have the resources to make this feaseable and cost effective. Instead of trying to sell of my X Which I love and know up and down, and then take on another possible car note, I would rather spend a few grand in upgrading a vehicle I would like to drive for the next 10 years. I have some money to throw around, and my place of business has a massive work shop equipped with every tool I'll need, a full metal fab shop, tig welder, Bridgeport mill and cnc machine all at my disposal. Not to mention my greatest asset, the EF!

So at this point I will be doing some research on the best route. Find a second Gen with a blown motor and use it as a donor rig, or even go full ifs with it. I'm assuming that unless I can find a donor sport trac I will need to find a longer driveshaft at the least if i just use a regular X, among tons of other research that will be needed. I presume that I will need to switch things like the ecu and gauge clusters and all those bits and pieces as well.

So while this will be a long term endeavor, and I am just in the preliminary stages of seeing if this is possible, anyone of you (especially the sport trac yodas like rebel, offtrac, and ranchero) are totally welcome to chime in on this post. Please drop a line, even if its an argument as to why I shouldn't waste my time with it,maybe you can talk me out of it!

So my first step will be reading up so I can see what I'm really in for. Hopefully I can start turning wrenches by summer. Cheers!

 

[MidnightRebel07]

For strength, cost and ease of doing a 4wd conversion I have three little letters for you...

SAS followed by a manul transfer case.

Way easier, cheaper and stronger in the short and long run.

Others have done this (SAS) 2wd to 4wd conversion.

 

[01STrunner]

I think this would be an awesome project to undertake. I wish I knew what the 2wd front suspension looks like to at least see the difference between the 2 models. I like your thought process about learning and not just going out and buying another ST. And I fully understand the urge to keep the vehicle youve put a lot of time and effort into, not to mention it looks really good. If only you werent in CA I'd just give you my IFS parts as they will be gone by next Tuesday or Wednesday. I do agree with Rebel about the SAS just because there are so much fewer moving parts to wear out not to mention a D44 is much stronger but I feel like it could be easier welding in the 4wd components from the same type of vehicle.

 

[05dakotatrac]

honestly SAS is stronger but not necessarily easier. taking a donor sencond gen or a trac for factory donor parts is easier. on the flip side though the factory IFS is rather limiting in flex and obviously more complex in the sense of more moving parts. downfall to a SAS is that custom fabricated parts are a must. and a complete steering overhaul is needed as you cant use the trac's factory rack and pinion set up. so many options and ideas to think bout before diving in

 

[LONO100]

My first steps will be attaining a chilton and haynes books, and then picking the brains of the guys at my ford dealership and all the mechanics i know. Then if this looks doable, ill start collecting parts. Right now with my limited knowledge on the topic and my access to a tig welder, metal shop and wiring, it looks like sas if i can find a decent axle. Then the next step is sourcing a tranny. The steering column and electrical look to be the biggest hurdles.

 

[MidnightRebel07]

Steering is easy, check out Chad's Trac as well as any of the 2nd gen Ex's (95-01), 3rd Gen Sport's (01-03) or any Ranger's (98-10) as they share the same designs as our Trac's. Most use a 1st Gen Ex steering box and just plum that into the RBV'sfactory power steering setup. Then just get some shaft extensions or make them and some steering u-joints. It's easier then it sounds and looks.

The biggest problem I think you'll have with trying to remove the drivetrain (mainly the crossmembers, bracketry) from the donor vehicle it how will you cut it off and retain the factory brackets, crossmembers with all the metal to realign/ weld onto your Trac without removing too much. It can be done but I think it's actually more fabwork then just welding in a crossmember and shackle mounts for the front axle, which is already made and used by plenty of members...

http://mail.explorerforum.com/forums/showthread.php?t=311454

http://www.sky-manufacturing.com/new/detaproduct.php?id=197

 

[01STrunner]

You're not kidding. Steering is the hardest part of an SAS IMO.

 

[mounty71]

I have been racking my brain thinking about doing this the past few months, since I found a guy parting out the entire front end of his Ranger Edge, and his axle has matching gears to my 4.10 rear end. I've been wanting a 4WD vehicle ever since I began offroading 8 years ago, but over the past 8 years my wants and needs have changed a lot. For the type of offroading I do, 2WD is perfectly fine and far more common than 4WD, and although it would be a nice luxury to have, 4WD can actually be limiting in my preferred area of offroading. I'm at a point where I need to decide which direction to take my truck, and now that I actually have the opportunity to make my current truck (which I would never sell) 4WD, I think I'm going to pass on it. For me it would mean losing the ability to run lift spindles and losing ground clearance, and I already scrape in deep two tracks. 4WD IFS also limits the amount of suspension travel you can achieve. And a solid axle is not even an option for me. (blasphemy!)

I fully support converting to 4x4 IFS though if you want 4WD but don't want to cut up your perfectly good truck. From what I know the axle will bolt in, then it's just a matter of swapping out spindles for knuckles with hubs, stub axles, and rotors up front. Either swap out the tranny tailshaft for a 4WD one or swap the entire trans, then add the t-case (manual would be easiest) and driveshafts. I wouldn't be able to use stock driveshafts because I have the 5.0 and would need a BW4406, but you could use stock ones. It almost seems like a no brainer considering so much of it is bolt-on. Down the road you can get BTF's new 4x4 LT kit too.

 

[MidnightRebel07]

Mounty, you guys live in the same area, why not meet up and go wheelin' with each other?

 

[mounty71]

Ya, I've asked a couple of times, and I'm sure eventually we will meet up. I'm new to the area so I don't really know what's around here. There's a trip in the making for this summer in the Sierras though.

 

[LONO100]

This summer we will definitely get a run going, just got to wait for the snow to melt. Already this thread has given me a lot of info and ideas as to what direction i should start my quest. I think the decision as to whether i go ifs or sas will depend on what i will be able to source. Keep the ideas and opinions coming and i will continue to post what i find out.

 

[mounty71]

What gears do you have Lono? The parts I was thinking of getting are for sale at a pretty good price.

 

[LONO100]

4.10. I had a shot at a 2000 explorer with a blown motor right down the street from where i live but someone just bought it. Its ok, there are tons of explorers out here for the picking. Btw, since you are
New to the bay area let me know if you ever need a suggestion on good places to eat or things to do, i can point you in a million great directions out here.

 

[Mike's brother]

Great stuff here, and I'm looking forward to following your build no matter what you do -- but I'm with Midnight on this one. Every project is more time, more money, more hassle and way more fun than you ever expect going in. If you don't have to worry about this as your daily driver, and you have the time and the money to work with, why not come out the other end with the best setup possible? I'd go SAS.

 

[LONO100]

yeah, i have an extra vehicle, and i no longer commute in my truck since i take the train to work these days. i also have a nice big shop here at work if i need any tools.

sas seems like the best setup, but im thinking im going to have a hard time finding a proper axle, and i have virtually no knowledge when it comes to modifying steering set ups.

with an ifs, i think it would be easier to find the parts i need to make it happen and at a lower cost, not to mention it would be more bolt on, and less fabricating that i would have to do. i could just find a donor X and the majority of the parts i would need would be right there and ready for the picking.

decisions, decisions! im going to order a chilton manual and start yapping it up with some mechanics i know. like i said, this will be a long term project, im hoping to get it done within the next year, but im sure the learning and planning will take a while if i want to do this right, and safely. the education continues.

 

[jjaganashi]

A 4WD conversion is pretty simple...
there is really only 2 components you need to accomplish this task..
SAS, if you want cheap and easy, run a d30 and some 33's with the SAS.
Then you can keep your factory motor and trans and just run a divorced t-case.(t-case is remote mounted and runs a mini-driveshaft from trans to t-case).
thats the simplest way of doing what you want to..
ive done the swap in a early 90's ttb 2wd f150(it was cake)
i got a front axle from a 79' f150 D44 and the t-case from the same truck.. i used the fatory trailing arm brackets for the radius arms, the factory coil buckets and steering gear and the front was done. just mounted the t-case a few inches rear of the trans and had a stubshaft milled that coupled the 2..
very simple, this was a 2 day project.(not counting haveing driveshafts made).
granted it will be a bit harder with your ifs Trac.. but leaf spring it.. very simple

 

[shooterdude199]

look at it this way.... look at all the guys on here like hugh or patrick who have the ifs 4wd sport tracs. they both want to do an sas. i think you should just go for the sas and skip the ifs 4wd step because eventually you'll want to do an sas. as for a front axle, i'd get a dana 44.

 

[OffTrac]

The grass is always greener...

 

[LONO100]

yup, at this point fate and opportunity will decide which way i go. hopefully i can itemize a list of things i will need and then a solid axle will cross my path.

 

[shooterdude199]

do yall have any pull a parts out there? you could pull one a 44 from an old f150 or old bronco.