4wd Conversion

[DieselDeaf]

ESOF stands for electronic shift on the fly, another fancy word for that little sissy switch that they have on the dash that makes it go into four wheel drive. Real 4x4's have a lever in the floor and you gotta get out to switch in the hubs. Some may disagree but the ESOF systems are prone to failure.

The front coils will let you turn sharper and ride better. At least that's what I am told.

As far as I know Excursions never had either of those features.

[BlazinTimes]

Thanks DieselDeaf!

I always hated Ford's ESOF switch functionality. I had nothing but trouble with my '99 Expedition. Loved the AWD but going in and out of 4WD sucked.

The Excursion has the hub switch so I assume it can be done using either method. I like the idea of the coils for better turning. My 2WD Excursion before this was awesome in the turns. I'm guessing it's a load issue for having one versus the other.

Really wish they would have had AWD in these trucks.

[vegoilrecycler]

Hey guys. I know this thread is a little cold but I'd like to get it started back up again. I'm in the process of looking for a donor truck or parts for my project.

I've got a 2000 F250 2wd Lariat Crew Cab with 166,000 on the 7.3L. She runs great and will likely continue to run great for another 300,00 miles or more (but that's another show).

I'm very interested in putting together a collection of good, reliable information on doing this conversion. Pictures, procedures, experiences, what bolted on, what needed modding, what parts were used, etc.

For as many guys have actually done this conversion, I think it would be a HUGE benefit to those (such as myself) who want to do this or who are thinking about doing this.

There are no more 7.3L being manufactured and this power plant is undeniably the envy of almost every Ford Powerstroke owner I have talked to who owns a 2003-1/2 to current year model.

With all of the strong interest "out there" in doing this, I invite all you guys to contribute your wisdom, pictures, feedback to a new thread that I'll start on this forum. I'll start a new discussion to get things rolling with a clean start.

Here it is: 1999-1/2 to 2003 2wd to 4wd Conversion: Collection Bin

[44boggers]

if it makes any difference
mine is being converted to 4wd right now
by a guy alot in southern tenn, north bama may know, bubba at rocking p diesel
they way i went was to call a guy i know at a local junkyard and get him to cut a front frame section with all suspension, axle, steering whole nine yards from a wrecked truck
then got the floor shift case i wanted and drive shafts, bubba had tranny parts and haul it to him
waiting on him to call and say come and get it
the cut frame section was a life saver cause it has all bolts and you know where everything goes
would have done the front end stuff my self but got a good deal

[vegoilrecycler]

Interesting news. I think I've located a front and rear axle from a 2005 for $900 total.

How do I go about selecting a transfer case? 4-Link for the front? Lift kit for the back?

Does anybody here know what's involved in installing a transfer case to a 6-speed manual tranny? Then how do I control the electronic motor on the transfer case and locking hubs?

Thanks for the help. Anything would be beneficial.

[44boggers]

six speed is same as auto need to have rear output swaped to 4wd shaft
if you decided to go with the newer coil set up just make sure you have everything off the frame suspension related
as far as t case thats up to you as long as you find a manual that shifts smooth and turns good or an ESOF im not sure how to check them
also with the ESOF you need the vaccum lines and tranny t case harness and the dash switch
the wiring for the dash switch shout already be in the dash just dead clipped to the back side of the dash

[44boggers]

on another note mine rides better with 4wd leaf spring front than with 2wd coils and seems to turn about the same
got lucky and didnt have to do anything with rear suspension and sits level no ass sag or lift
just need to drop carrier bearing about an inch has small vibration when taking off hard

[vegoilrecycler]

Originally Posted by 44boggers

six speed is same as auto need to have rear output swaped to 4wd shaft
if you decided to go with the newer coil set up just make sure you have everything off the frame suspension related
as far as t case thats up to you as long as you find a manual that shifts smooth and turns good or an ESOF im not sure how to check them
also with the ESOF you need the vaccum lines and tranny t case harness and the dash switch
the wiring for the dash switch shout already be in the dash just dead clipped to the back side of the dash

44Boggers,

So the output shaft on the transmission needs to be changed? What about the tail portion of the tranny case? I'm probably better served to find a spare 6spd and try to get the parts together.

As far as the front axle that I've got my eye on, I don't have access to a frame to take parts from. So where does that leave me??

As of right now, I'm leaning toward a manual controlled Transfer Case instead of ESOF and manually locking the hubs instead of a complex vacuum controller. I wondered if the wiring for the 4wd controller exists in the dash because I saw it when I changed out my radio. This seems to be the easier path unless somebody can give me clear instructions on how to retrofit my F250 with the 4wd electronic and vacuum components.

[44boggers]

yeah the ouputs have to be changed and when you do you do away with the tailshaft housing off the 2wd tranny
as far as the parts off the frame the best bet is find a boneyard with a truck you can salvage from thats the cheapes as from ford would cost quite a bit
the floor shift case is easy to make the dash lights work you need to but a tranny harness from ford relativly cheap and remove dead plate from under carpet and carefully cut carpet and install shifter on case

[vegoilrecycler]

Here's what I'm thinking...

Divorce Mount Transfer Case
4-link front kit with 4" lift in the front and 3" in the rear for a level stance.
2005 or 2006 Dana 60 Driver drop front axle
2005-2007 18" or 20" OEM wheels
1.5" Steel wheel spacers for the rear axle to compensate for the negative offset OEM wheels

What to decide:

What 4-link kit with springs should I get for the front?
What rear lift kit should I get for the rear?
What transfer case should I get? Do I attempt to use an ESOF controlled T-Case or manual shift? Do I attempt to tap into my vacuum pump for the hub locks?

Any opinions or insight would be helpful.

Also, will my 2000 spring buckets work with the 2005 axle or should I get the 2005 spring buckets? Burning in the new buckets isn't a Mega problem but there's no reason to do it if they are similar enough.

Thanks.

[44boggers]

you have to swap buckets to get the right height
and finding a good divorced case might be an issue
but other than that i like manual hubs better less to go wrong

[vegoilrecycler]

Originally Posted by 44boggers

you have to swap buckets to get the right height
and finding a good divorced case might be an issue
but other than that i like manual hubs better less to go wrong

Help me understand what challenges you think I will run into with installing a divorce mounted transfer case? With a DMTC, I could theoretically select any transfer case that has the same off center front hub spacing. The control for the transfer case could be manual as far as I am concerned. ESOF is not important to me.

What transfer cases are good candidates for divorce mount? Is there some reason that I couldn't use an OEM manual shift TC?

[DieselDeaf]

The NP271 and NP273 transfer cases are just about the strongest units around. They are designed to bolt onto the back of a tranny with a intermediate adapter and have no provisions for mounting to a crossmember.

Why are you wanting to make it so difficult?

[vegoilrecycler]

Originally Posted by DieselDeaf

The NP271 and NP273 transfer cases are just about the strongest units around. They are designed to bolt onto the back of a tranny with a intermediate adapter and have no provisions for mounting to a crossmember.

Why are you wanting to make it so difficult?

Thanks for the insight on the transfer case options. I'm not intentionally trying to make this a difficult process. What sounds difficult to you?

Send me an email if you prefer. info AT dfwbiofuels DOT org

[mrwrench]

what are the differences between 07 and 08 front axle ?