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Old 10-25-2010, 02:47 PM   #1 (permalink)
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4x2 to 4x4 with a SAS

i have a '96 f150, its my DD... but as ideas grow its becoming more of a mud toy.. in my head that is, so far this is my parts list, tell me if i'm missing something or if i'm taking a wrong direction..

1. D44, rad. arms, and rad. arm mounts from a '78/'79 f150/bronco
2. 4" lift coils or 6" (have not made my mind up, a guy on FTE made his work with 4 and didn't have to cut the engine x-member)
3. 92-97 F350 drag link or one from JBG
4. a custom made trac bar, or modify one from the '78/'79 axle i'm looking at..

Thats pretty much all as far as getting the front end set up

now to change that retarted 2wd drivetrain to the way its supposed to be

1. a 4wd tailshaft for my M5OD-R2 (will this work??) if not either a ZF-5 or a 4wd M5R2
2. BW 1356 T-case, or would the NP 205 be a better choice considering this is a DD at heart?

I cant afford a '95-'96 4x4 to trade in for mine so thats why i'm doing the swap..
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Old 10-25-2010, 03:31 PM   #2 (permalink)
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It is nice to see someone who researched before asking questions and has a good game plan before jumping in. You are right on track with the front end setup and have it pretty well covered, you can change the output on your tranny and put a tcase on it although it would probably be easier to find a tranny, tcase combo to swap in. As far as the 205 vs 1356 it depends on what you are going to do with the truck besides dd it and what is easier to get where you are.
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Old 10-25-2010, 04:04 PM   #3 (permalink)
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It is nice to see someone who researched before asking questions and has a good game plan before jumping in. You are right on track with the front end setup and have it pretty well covered, you can change the output on your tranny and put a tcase on it although it would probably be easier to find a tranny, tcase combo to swap in. As far as the 205 vs 1356 it depends on what you are going to do with the truck besides dd it and what is easier to get where you are.
well i been riding fourms since i was 14, 17 now, and i finally figured out how to not get flamed.. and over on FTE there is always noobs in the '87-'96 area askin about loud exaust, headers, or something simple like that, when all they have to do is search the sub fourm and they'll find 100,000 threads on it.. pisses me off to no end..

but this truck will be 95% dd and 5% trail/mud truck, soo which T-case/tranny would suit that best?
i was going with a "good enough for stock, good enough for me" build with this after i got to reading about the TTB just because its a bolt in swap, i was considering this, but i always get talked into doin stupid crap, and i don't want to break somethin that i put that much time/money into..
also the SAS is just WAY WAY cooler than the crap TTB
i have the M5 now and i like the street manner it has, but like i said i dont wanna go out the 1st or 2nd time and stomp it and pop the tranny, i really dont think my stock 302 is going to do that but still..

Also, that little info i figured out.. that was many long nights and many tins of grizzly wintergreen
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Old 10-25-2010, 07:29 PM   #4 (permalink)
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I understand where you are coming from as I'm only 22 but I think a zf with a 1356 will hold up fine for what you are doing especially mud. I will try to help you as much as I can since I have already done the swap on my 93
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Old 10-25-2010, 08:25 PM   #5 (permalink)
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A ZF would for sure hold up, but I would think an M5od would hold up just fine in mud too. I had a 97 F-150/ 4.2L/ M5od when I was in High school and it held up just fine to all of the abuse a dumbass kid, trying to make up for not having a V8, put it through.

OP, as for the Tracbar, I have the full front end from a 77 F-150 sitting in my shop now, and it appears that the stock tracbar would be extremely easy to make work on your truck.
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Old 10-25-2010, 09:08 PM   #6 (permalink)
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but i always get talked into doin stupid crap, and i don't want to break somethin that i put that much time/money into..
If you don't want to break stuff, then perhaps you should look for a D60 (and a 10.25" rear to match). A D44 is a D44, TTB, SA, whatever. They tend to break the same.

The M5OD is decent, though nothing special with it's tallish 1st gear. It should hold up fine as long as you don't go side-stepping the clutch.
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Old 10-26-2010, 03:46 AM   #7 (permalink)
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If you don't want to break stuff, then perhaps you should look for a D60 (and a 10.25" rear to match). A D44 is a D44, TTB, SA, whatever. They tend to break the same
i was considering the D60, BUT this is my DD i dont need 3/4 ton axles to go down to wall mart then saturday nights go to the river or mud pit.

if i ever build a strictly trail/mud truck i'm thinking i will take my '87 and throw a D60 front and D70 rear...or the 10.25 for the rear, but i may have to sell my '87 soon..

thanks for all the responses guys
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Old 10-26-2010, 06:32 AM   #8 (permalink)
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what size tire are you planning on running? what engine?

if it was my DD, part time playtoy, i would go 33's. if you go with the ZF, you will never have to worry about it. I would not use the 205 in your case, get a 1356. you will have a better low range and can keep your gear set a little higher in the diffs for driving on the highway. also look into getting a set of lockers. lockrites will be fine. with all 4 pulling, you will have a hellafun time in the mud.
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Old 10-26-2010, 01:19 PM   #9 (permalink)
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what size tire are you planning on running? what engine?

if it was my DD, part time playtoy, i would go 33's. if you go with the ZF, you will never have to worry about it. I would not use the 205 in your case, get a 1356. you will have a better low range and can keep your gear set a little higher in the diffs for driving on the highway. also look into getting a set of lockers. lockrites will be fine. with all 4 pulling, you will have a hellafun time in the mud.
i was thinking 33's too, and then when the big bog ins come around have a set of 35's already mounted on some crap work truck rims or just a cheaper rim to throw on for the few bog ins it'll be at..

the engine is a 302 with just a few ugrades, mainly just accel 300+ wires, stock style single plat plugs with a larger gap .50 is what i remember doing but it could have been .45, MSD blaster coil (not in yet) and MSD HP cap and rotor kit. and exaust...

if and when the 302 pops i may build up a little 306 to be bullet proof, or a 351w..

the lockers are planned but they may have to wait, also i was thinking the 1356 just because it would be easier to find/obtain in myy area..

agin, thanks for the resonses
i'm loving the forum so far, seems like y'all have a awesome group of guys and gals running it
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Old 10-26-2010, 01:47 PM   #10 (permalink)
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seems like y'all have a awesome group of guys and gals running it
how dare you talk nice of us like this. take your noob ass downtown and head butt a high speed freight train, then drink a bleach and gas cocktail.


























































































































































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Old 10-26-2010, 01:55 PM   #11 (permalink)
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i'll get right on the gas and bleach cocktail as soon as you get off my cock
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Old 10-26-2010, 02:00 PM   #12 (permalink)
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If you don't want to break stuff, then perhaps you should look for a D60 (and a 10.25" rear to match). A D44 is a D44, TTB, SA, whatever. They tend to break the same.

The M5OD is decent, though nothing special with it's tallish 1st gear. It should hold up fine as long as you don't go side-stepping the clutch.
Just be glad he decided to go with a SA, he was wanting a TTB there for awhile..

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Old 10-26-2010, 02:06 PM   #13 (permalink)
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Just be glad he decided to go with a SA, he was wanting a TTB there for awhile..

dam it... drago, how the hell did you find me over here?
...and don't be pickin on me, i'm as hard headed as a mule ok?
........read my user name over here "dumb kid"..
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Old 10-26-2010, 02:21 PM   #14 (permalink)
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dam it... drago, how the hell did you find me over here?
...and don't be pickin on me, i'm as hard headed as a mule ok?
........read my user name over here "dumb kid"..
Ah shucks; Now where would the fun in that be..
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Old 10-26-2010, 04:04 PM   #15 (permalink)
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Ah shucks; Now where would the fun in that be..
true.. but on the upside i found a D44 that is perfect for my swap, now to find the cash
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Old 10-26-2010, 06:11 PM   #16 (permalink)
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Just be glad he decided to go with a SA, he was wanting a TTB there for awhile..

I really couldn't care less. D44s don't belong under a fullsize truck built for wheeling in any form.
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Last edited by 4x4junkie; 10-26-2010 at 06:12 PM.
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Old 10-26-2010, 06:16 PM   #17 (permalink)
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Yeah I really cant argue that...
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Old 10-26-2010, 06:57 PM   #18 (permalink)
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Another vote for BW1356, dime a dozen at J/Y's. Get a manual shift one from a ~1988-96, it will have a fixed flange output (break rear shaft, remove, drive home = D.D. friendly. Shoot for a SBF ZF5 if you can. They can be $$ but I have found 2 at Pick & Pulls and only paid $80 each for them.

If you can, try and find a BW-4407 out of a 1996-97 F-250/350. Very stout, but can be hard to find.

Thank you for researching before posting.






















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Old 10-27-2010, 03:38 PM   #19 (permalink)
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whats with all the noobs bashing noobs in here?
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Old 10-28-2010, 05:40 PM   #20 (permalink)
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a ZF5 is 450 bucks here from the JY with a warnty, but i have issues with the JY here so i may be travling up the road to moltrie or adel to a "pick you part" as they call it...

anyone interested in a 1987 F150 with 302/m5od-r2 2wd?
i got to sell that thing to start this build...
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Old 10-29-2010, 05:39 PM   #21 (permalink)
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whats with all the noobs bashing noobs in here?
Hope you weren't refering to me, I lost my old account information, been on PBB since early '05
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