2WD to TTB swap

[rangerin]

First off, sorry for asking such a common question, but I didn't find anything specifically addressing first gen rangers with a 2WD to Dana 35 swap.


This summer's project was converting the ranger to a 5-speed. Next summer's project is to put a Dana 35 up front. I'm not looking to bash the truck, I simply like working on it and I'm tired of getting stuck in dewy grass. Besides with all the ice NC gets in the winter, 4WD would be much appreciated.

I've already collected a few things (manual 1350TC and front drive shaft) but other than the front axle, engine cross member (from a 1st gen), and manual hubs, what else will I need? Will my current brakes, radius arms, springs, etc work? Basically, I'm looking to find out what I should grab from the Dana 35 ranger.

 

[Captain Ledd]

That's because 2nd gen and 3rd gen are basically the exact same thing. The system remained virtually unchanged up to and including 1997.

1995-1997 had better brakes. They used pins to locate the calipers instead of those ridiculous wedge things. If you have a choice to source parts from, get an axle from those years. Rotors won't interchange between 2wd and 4wd but I believe the calipers will (except wedge and pin respectively).

General list is this:
TTB axle, hub to hub
4x4 engine cross member and 4x4 brackets OR lift brackets that attach to 2wd member (custom, you build). Generally the 2wd crossmember doesn't have clearance for the 4x4 stuff at near stock height, needs about 4" lift minimum.
Front driveshaft
4x4 rear driveshaft
Transfer-case
4x4 transmission (either converted 2wd trans or 4x4 replacement)

Springs can be re-used, radius arms can be re-used, shouldn't need anything steering wise.

Most just do a frame swap, but converting TO TTB in any form is not for the faint of heart. SAS's are much easier. If you're not looking to lift it or bash on it, spend some time considering a low pinion Dana 30 (clearance), and building a new engine crossmember with more clearance for the D30 center section to keep the height down.

Getting stuck on dewey grass sucks, it's a large factor on why I put a locker in my 2wd.

 

[rangerin]

Thanks, that's exactly what I needed to know. The project doesn't intimidate me, I've done far worse in the past.