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50% two wheel drive to four wheel drive conversion

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55K views 104 replies 31 participants last post by  samsonjohn  
M
#1 · (Edited)
I decided a while ago to convert my carbed 86 2wd to 4wd, and have had the parts to build different stages of the rig about 5 different times. This weekend we are going to put the truck under the knife and see if we can do it. The specs are nothing all that unusual to the board, but here they are anyway.

Chevy's in the rear
Rears up front
dual cases
W56 transmission
85 front axle
Tacoma rear axle
welded front and rear
kongs high steer (with Dana44 studs)
35" MTR's
etc.

I'll also post issues occured that I don't remember from past SAS's, and how we dealt with these problems. They'll be numbered in individual posts through out the thread.

The swap is going to happen over a GJC's house, and we should have everyone from 50% as well as other people from the board over at different times to lend a hand. Preliminary pics up soon.
 
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M
#4 · (Edited)
In my opinion the 2wd frame is the way to go if you don't have a solid axle frame to work from. The IfS frames have less room above the front axle than the two wheel drives or the solid axle trucks. So in thoery this helps with room for up travel. You do have to source a few extra things for the swap (a rear axle, a tranny, a cross member, etc.), but if you can get ahold of these things cheap, then it isn't really that bad. I chose to use the 2wd because that's what I had to work with, and I'm tired of seeing all my friends go on runs, and talk about them later. So a 2wd is what I am going to use.
 
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#6 ·
Without a doubt the 2x frame is the choice frame to build off of. Ill never build another yota froma 4x again. Your gonna change damned near everything anyway why not start with a good and cheap rig?
 
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M
#23 · (Edited)
Ya, it isn't the most stable thing in the world, but it seems to be holding up alright.

Work is done for the day, but I figured I would give an up date. Thus far we've got the front suspension torched off the frame and it is ready for grinding. I have to thank the RE:Todd for that (watch those fuel lines todd :D ). The rear axle, stock springs, and drive line are out, and the chevy springs are hung. A local fabricator is sponsoring me for a front hanger and should be dropping it off tonight. We'd like to get the front supension in and the front axle hung tomorrow, as well as the rear axle. Cut out the stock crossmember, hang the tranny, and see if we can't get some wheels on this thing. The original goal was to make frostoberfest, but it doesn't look real promising at this point. We got some other pics today and will post them later.

"The Boy" also came by today to help out and would like to say waaazzzuuup to those who know him, (you know who you are :D ).

1.) first issue occured: on the two wheel drives, the horseshoe collar piece is further back than the four wheel drives. So when we wen't to place the front hanger in for the chevy's it landed right where the horseshoe collar getts welded in to the frame. To fix this, we ground down the part of the collar that comes in under the frame, and just welded the hanger in.
 
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M
#26 · (Edited)
Ya, so today wasn't nearly as productive as I was hoping it would be due to a couple of hang-ups as well as rain. We got the front frame rails somewhat ground down, removed bits of brakeline that were still hanging on the frame, as well as E-Brake cable.

2.) The stock E-Brake cable will not work for this conversion. On a 2wd, the stock E-Brake "Y"s off at the back of the crossmember, and goes to each wheel individually. on a four wheel drive, it's a single cable to the axle, then "T"s off on the axle itself. Our solution to this is going to be to eliminate the whole E-Brake assembly, and use line locks at a later date.

Started working on the front and rear axle (winor welding was needed), and drank a few beers. Times were good. One issue we ran into was putting the shackle tubes through the frame for the front shackles.

3.) The two wheel drive trucks have a different slant on the bottom of the frame rails that the IFS trucks. SO if you end up ordering tubes and jigs, then be prepared that the jigs can't just be slapped into place to use. They have to be fenaggled with a little bit. Our solution is going to be what desertoy suggests later in the thread, and use two plates. (read further for further explanation).

I ordered my tubes from Marlin. I didn't order the jigs as a friend who has done this before mentioned that the jigs don't work very well on the 2wd frames. So know I'm trying to figure out how to get them in there straight. I'll do a search tonight, but if anyone has any ideas then I'm all ears. I have to say thank you to yodajack here on the board as he is the local fabricator who made my drop front hanger. It is seriously beefy, and I will have pictures up tomorrow as well as details.
 
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