97 4.0 convert to 4wd

[boostedjd]

i have a 97 2wd and was planing on converting it to 4wd. I'm looking to use a manual transfer case as everyone seems to have problems with electronic ones. Can i just get a 97 4wd transmission, tcase, and driveshafts? Also heard of people using divorced tcases so you dont have to swap over transmissions and that does sound easier, anyone have any experience with this or know what kind of divorced tcase would work best? But also looking to still be able to daily drive so keeping stock gear ratios makes me lean toward stock 4wd components. or just swap out tailshafs on my auto trans to fit a tcase if thats possible? Any suggestions or advice would be extremely helpful, thanks

 

[adsm08]

Hi, welcome to the forum.

This is a topic that has been covered EXTENSIVELY, especially recently. Please search as I know I personally have explained this to no less than 4 different people, in as many threads, in the last 8 weeks and I am frankly quite tired of typing out the same information over and over.

 

[boostedjd]

I got the np205 divorced case is common, and everyone says just buy a 4wd but there are none of the twin I beam suspension type within reasonable distance of me. Guess my last question is I've read on a diff forum that you can just change the tail housing on a 2wd to a 4wd housing and then just bolt up the tcase, but only found this in one place so anyone know if it's true?

 

[adsm08]

Alright, I guess I will have to go over this again.

1) You can't throw an extension housing and t-case on a 2wd trans to make it 4x4. The output shaft lengths, diameters and spline counts are all different.

2) You can't just bolt a 4x4 front axle in a 2wd chassis. The engine cross member is also drastically different, especially in the areas where the axle actually mounts to it.

To change said cross member the following must happen:

1) Engine has to come out.
2) The cab must be blocked up.
3) The steering box must be removed.
4) Steering box reinforcement has to be removed, this involves cutting 3 welds and several rivets.
5) The engine cross member must be removed (obviously). This involves cutting out a further 8 rivets and 4 welds.


Oh, and you gotta do all that twice if you rob a cross member from a junk yard.

Generally on a 2wd to 4x4 swap it is easiest to deal with the front axle by doing an SAS and lifting several inches.