4x4 conversion possible?????

[Racenut]

So I was under the Expedition a couple of weekends ago replacing the transmission, when I noticed a large conector mounted to the floor board at the tail of the trans. It has a cap plugged into it and I found out that the Expedition is prewired for either 2wd or 4x4 (also have the plug for the 4wd selector switch to the left of the stereo under the vent).

So this got the wheels turnin in my head about 100mph!

My question is since the Ex has a different frame than the f150 ( I hear the f150 is a PITA for this conversion unless going SAS because they use two different frames) is it possible if I where to get a donor front frame clip (for all braketry and suspension, there are 4 locally for about $300) T-case (local $150), Front Axle ( local with matching ratio $150), and the 4wd Transmission (local $500) does this seem like a doable project (would also look at getting the Fabtech 6" lift and 35x12.50's to go with it).

Could some one on hear post some pics of the 1st gen 4wd front suspension (mainly the engine cradle, front axle mounts, Torsion bar mounts and the A arm mounts)? This will give me something to compare to see how hard this project would be.

I know it will be alot of work and a fair amount of $ ( Call me crazy if you want ) but in the long run I think it would be worth it to me, since I will drive her till she dies and then rebuild her again ( If you can tell I hate car payments).

I love my Ex and since it is almost paid off I would rather try and tackle this project if it is possible rather than buy a different one (plus I only have 120k on this one instead of most I see with around 200k).

Ideas, comments and sugestions welcome since this is just a thought!

 

[99 Expy]

I will try to get some pics for you soon, it is snowing today, so they might turn out crappy. I had a bunch of pics when I changed all my bushings and control arms, but they are gone now

But if you can find all the parts for a good price, I think it would be a good deal, and I would recommend getting new bushings and changing them before you put all of it together so you have a whole "new" front end.

 

[Racenut]

I will try to get some pics for you soon, it is snowing today, so they might turn out crappy. I had a bunch of pics when I changed all my bushings and control arms, but they are gone now

But if you can find all the parts for a good price, I think it would be a good deal, and I would recommend getting new bushings and changing them before you put all of it together so you have a whole "new" front end.

I would appreciate those pics and regarding the bushings if it seems like a doable project I would upgrade to all greasable polly bushings. Thanks for the input .

 

[99 Expy]

I got some quick pictures last night, but if I go home next week, I will be rotating my tires, so I could get some better pics.

 

[99 Expy]

Hope these help. Mine is a 99 XLT by the way, but should be similar to yours. And when I rotate my tires, I will get some pics of the mounts.

 

[Racenut]

Thank you for the pics, this will give me something to start looking at for comparison!

 

[99 Expy]

I have the 4.6, so I think my axle might be different than yours, but the mounts and everything will be the same. If there is a difference, make sure to go with the bigger axle since you have the 5.4, and throw in a locker diff to make sure you do it right the first time

 

[Racenut]

I will definatley do it right the first time. Right now I am just looking to see if everything will work ( which I belive it will ) then it will be time to save up the money.

My son is due to be born tomorrow so it will easily be 6 months + till this gets done, but that will give me time to round up all the parts and have everything sitting here waiting

 

[99 Expy]

Haha, i hear you on saving the money. Getting the ideas is always the easy part, but money always slows you down lol. Congrats on your your expecting son. If you do the project right, who knows, maybe it will be his some day lol.

 

[panda24619]

yeah congrats man! but it should work out good. and the front axle is the same for both the 4.6 and 5.4. so no worrys there. you will have to do some welding though. since i think the front cradle is welded to the frame. ill have to look. im going to be busy once i get off here, so cant take any pics, but ill try and get some up this week for you.

 

[Racenut]

Thanks you guys for all the responses I really appreciate it. We are really excited for the addition to the family, we got lucky and had my daughter and now my son so no more for us ( once I pay of the Ex then I will have to get my wife a new mini van).

I am pretty sure there will be a pretty fair amount of welding involved in this project but thats no problem, me and a few buddies went in together on a 140 amp miller mig and we also just put on a 15'x19' addition on to my buddies shop (now its 28'w x 19'd and 10.5'h) makes large project alot easier.

One of my buddies has a TRUE '69 chevelle SS 396 and the other just picked up a '84 Grand National T Type, so we always have something goin on between side jobs and messing with our own rigs!

 

[jacks3am]

do it dude ur expy is sic and it would be that much cooler 4x4!

 

[panda24619]

but also dont cheap out. if your going threw all that work it would be a lot easier to just put a solid axle under there. find an ecu and everthing that will work an expo transfer case and find a junk yard D60 from a ford, or dodge, but the ford would be more reliable and easier to work on. and then put some leafs on the front, just like nvy is doing, but it should be easier for the front conversion since you dont have to cut much off the front.

 

[Racenut]

I thought about the SAS but i really don't do any major off roading. This is still my family hauler and I do alot of interstate driving, but it would be nice to be able to get to a few of the camp sites that we can no longer get to.

Once the days of family hauling are over then I will probably make this just my toy and then do the SAS because then I don't have to worry about putting car seats in or carrying a ladder for the wife

 

[jacks3am]

sas keeps its alignment better? i think its actually lighter overall too, but thats just somthing i saw

 

[walnuts4x4]

do a SAS and run 37s... I put my 3 year old into mine all the time and my wife is short too... only 5'3" and she has no problems... i would go bigger but see no point and now expy tows my boat too....

 

[JUST4FUN]

I think you would be better off going with the SAS and a manual transfer case just cuz of the electronics. if im not mistaken the fourwheel drive goes though the gem and the computer and the abs system and they need to be programed for it. i would think about selling it and buy a 4x4 and save the trouble and the extra cost, what you think it will cost now will be double or triple when you get into it. IMHO

 

[jacks3am]

i like your expy alot racenut, if ya wana go 4x4, just get a locker!

 

[treycool94]

i would get an sas if i had a 4x2 and doin wut u r but im a teenager lol