This should be fun!

Would it be possible/ feasable to convert a 2wd 2500hd to a 4wd. The front suspension appears to be the exact same torsion bar, just missing the transfer case, diff and cv joints. This would be working on the assumption you could get the parts from the wrecking yard. Are the 4wd Allison transmissions different than the 2wd?

Yes, I know most of you would say sell the 2wd and buy a 4wd, but what's the fun in that? Besides, you would have to outfit another truck all over again. http://www.dieselplace.com/forum/smileys/smiley18.gif

Bombs away.

I have done this a couple of times and helped on several others over the years, but not done a D/A. Trust me, it is FAR cheaper, easier, faster, and more satisfying to strip the 2wd of added accessories, sell it, buy a 4 wd, put your accessories back on (many will work), and enjoy the ride. You cannot believe the little extras it will take and most importantly COST YOU BIG BUCKS to make a change over. I've done GM and Ford, but in my old age and hopefully increased intelligence, I just say NO WAY! My wife of 37 years, whose first coffee table after marriage was a piece of cardboard on top of a new 327 engine I was building in the living room of our studio apartment (no garage) while I was going to law school, would definately divorce me if I ever started a project like that again, even though I now have a 10 car garage, tons of tools, and a overhead lift.

If the front is a direct bolt in meaning the frame is the same complete with any extra holes a 4x4 needs it wouldn't be any more difficult than doing your own lift kit. You'll need a Tcase which won't be cheap and the back end of the tranny is different. How different internally I don't know but that could be a hidden money pit. If you are lucky and they use the same tranny hump in the cab I'd go manual shift Tcase. Less mess trying to integrate the electronics.


Just because the IFS might bolt in I doubt you'll find one in decent shape complete without spending a ton. I'd consider a straight axle up front. A Ford Dana 60 would be easier to find. A custom set of springs and hand made perches. The biggest headache would be the steering. If your handy you could save messing with the tranny and run a divorced Tcase. Of course all this work might just get you the divorce!!!http://www.dieselplace.com/forum/smileys/smiley17.gif

Thanks for the replies! So far 2wd is my only regret with this truck! http://www.dieselplace.com/forum/smileys/smiley9.gif

The easiest way would be to find a wrecked donor truck (it could be a gasser) and transplant the parts.

The easiest way would be to find a wrecked donor truck (it could be a gasser) and transplant the parts.


That's exactly what I was thinking! http://www.dieselplace.com/forum/smileys/smiley32.gif

I have about 8.5 years left with this truck. I don't need 4wd, just would find it usefull every so often. Hence, a toy project. http://www.dieselplace.com/forum/smileys/smiley17.gif

Go for it by all means if you are mechically inclined and can jack the
trucks up "side by side" and have lots of air tools and jacks and such,
it will not be that bad at all really.