NO, I will not sell this truck and just buy a 4x4. If you came here to say this please kindly escort yourself out.

So I bought a 1996 Ford F150 4.9L inline 6 cylinder automatic RWD, Regular Cab/Long Bed. I am going to do this conversion and will not just buy a 4x4.

I'm going to be doing a six inch lift at the time as well since I will already be down there with it all apart, but I'm not including the lift part in this post. Most everything I've found out I've researched on my own. I have a well equipped garage, room for the truck, etc.

Parts List:
Front Axle Assembly (TTB axle, radius arms, coils, shocks, tie rods, drag links, pitman arm
Front Drive Shaft
4x4 Transmission (I have an E4OD 4x2 so I'm going to look for a E40D 4x4)
Transmission to Transfer Case Adapter
Transfer Case
Transmission Cross Member from 4x4 Truck
Rear Drive Shaft

Do I appear to be missing anything? Anyone done this and have tips/advice? Thanks, I'll be posting updates as they happen. May be slow going...

 

go buy a 4x4 ...... Just kidding. My advice would be to make sure you line everything up as best as you can and just double check as you do things, especially if you are drilling new holes for radius arms (I dont no whether or not you need to). But if you plan on lifting or doing anything specific be sure to do it all at same time. Also, do you know if your getting an electronic or manual transfer case/ how you are setting it up threw floor/dash. If its electronic make sure you hve the **** and crap it would suck to overlook such a tiny piece

 

I haven't put much thought into how i'm setting it up through the floor/dash.

Although do you know any benefits that would sway someone towards electronic over manual or manual over electronic in regards to the transfer case?

 

Forget the ESOF. That is just expensive fluff to fail. A manual shifter linkage is pretty rock solid with manual hubs, and the cutout is already in the floor under your carpet.

Next, if you are going to do all this work, why put in a crappy TTB? Dana 60 solid axle swap all the way. Get an F-350 donor for all your parts and you'll be good to go.

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