2WD to 4x4 Conversion

[Chuck "Classic Ford" JR.]

Okay, first let me start off by saying this - I UNDERSTAND that to most people out there, there is so much part swapping and money involved that it just flat out isn't worth it. I UNDERSTAND that the amount of time, labor, and funds involved would probably make someone think I'm crazy for asking.

A few months ago I was forced to sell my beloved 1986 2WD Ranger in order to pay for school after I got a new car and the engine blew in my truck. Since that time, I've kept up with Rusty's (my truck) new owner, and since buying the truck and promising to fix it up and put it to good use when he bought it in March, he's still not yet touched it and Rusty is just sitting there rotting away. If he still hasn't fooled with it by the time I get my money together I'm buying it back and treating it as it deserves.

As far as the engine, my friend who owns a 2004 Ranger 4x4 with a 4.0L is doing a 5.0 swap, and will not be needing his 4.0L engine and trans. Since I know his 4.0L will work in my truck with most of the vital systems and the engine mounts are the same, I was going to buy his engine and trans, swap the tailshaft from my A4LD since Rusty is a 2WD and drop it in. However, I really want to make a mud toy out of him, and since I already have a 4x4 transfer case and am not afraid to get deep and dirty with my modifications (after all, Dirty is my name) I'm asking exactly how difficult it'd be to do a 4x4 conversion. Mainly, I need some sort of idea for a parts list, and what will and won't work.

I know it's going to be a real bitch when it's all said and done, but this truck has all the sentimental value in the world to me and I want to do it up right if its new owners aren't going to do what they promised. Rusty was like a member of my family, and I can't stand to see family neglected like that.

 

[RangerSVT]

Since you're making it a mud truck, you're farther ahead than you think you are. SASing (Solid Axle Swapping) is easier done using a 2wd frame than a 4wd frame. Depending on how big of a tire you want to run will dictate which axle you need to look at using. For the purposes of this build (mud truck), I won't mention doing the jeep dana 30 swap, since it'll be weak.
You could run a dana 44 from an early bronco, its the ranger width, and matching 9" rear axles are fairly easy to find depending on your area (there's a guy in evansville on craigslist that has a pile of them he's selling), you could go 44 full width, or you can go with dana 60's. Again, it all depends on your intended tire size and use.
The other issue you will have is with the engine swap. While the 4.0 SOHC will fit in the ranger, its fuel system and electrical system is not directly compatible. The 4.0 uses a returnless style fuel system, the gen 1 ranger uses a return style. Different fuel systems, different fuel pressures.
The electrical system is also different, the 04 4.0 uses pats, which contains components from the dash and steering column. If you want to use the engine, I suggest using a 96-97 ecu and harness from an explorer, as this doesn't use pats. The fuel system, however, you will need to get creative...


SVT

 

[Scott B.]

Okay, first let me start off by saying this - I UNDERSTAND that to most people out there, there is so much part swapping and money involved that it just flat out isn't worth it. I UNDERSTAND that the amount of time, labor, and funds involved would probably make someone think I'm crazy for asking.
...

A lot of people say that, but IMO, on these trucks, that is not true.

You're not crazy - you have an idea. Can it be done? Certainly. Is it hard? Not especially. A little tedious tracking down parts, but most everything is bolt on. (SAS is weld-on) Is it worth it? If you like the truck, than yes it is. Besides, building your truck is fun and satisfying.

 

[Scott B.]

Since you're making it a mud truck, you're farther ahead than you think you are. SASing (Solid Axle Swapping) is easier done using a 2wd frame than a 4wd frame....

SVT,

Why is a 2wd frame easier to SAS than a 4wd frame, since both frames are the same?

(Not trying to pick a fight, only to pick your brain!)

 

[RangerSVT]

2wd frames have a different engine crossmember than the 4wd frames, so simply bolting in a TTB in place of the TIB is not possible. The crossmember on the 2wd's don't have the pivot brackets hang down as low as the 4wd's do, so you can get a solid axle under a 2wd frame with less modifying. There are many threads where members have done this. I'm currently building a 94 xcab ranger with full width axles, and I used a 2wd frame...

SVT

 

[Powerpat]

Can the majority of the crossmember be cut out since it is no longer has the forces on it from the TIB? I dont want to lift the truck very high and was thinking of using YJ leaf springs in my Dana 30 swap. Any thoughts?