Have been interested in a 4x4 Chevy van and would want the IFS suspension for road manners. I notice that the Express extended version is a 155" wheelbase. My 94' K2500HD x-cab LB 454 4x4 has a 155.5" wheelbase.

It is my understanding the Express vans use a full frame like the C/K trucks. Anyone have any knowledge of how close the frames actually are to each other, or details like mounting locations etc?

The 94 is OBD1 and I am sure the 96 and newer Express is an OBD2, so one issue unless using the Express powerplant.

Trying to figure out if there is a way to assemble a nice IFS 4x4 as a family road warrior without spending 50K through Quigley.

I know the quigley system uses 90% GM parts. I want to say the only quigley parts are a crossmember to mount the 4x4 lower a arms to and support the front diff all in one piece and a custom torsion bar bracket, the rest is new GM parts.
The vans share nothing with the pickups so thats out. I would like to buy the parts and convert my van over.

I got stuck four times leaving an event last month with the rally car in tow. Makes me want to do the conversion as well.

Is a suspension lift required to install the front axle or do they use a body lift?

If it is a body lift, mabey a 6 speed would fit under the van then?

No lift is required. There is some for sale listed on Quigley website.I think they were all gassers though.

Several articles I have read say the vans and trucks "do" share most parts. It was mentioned that the front differential housing needed to be a certain size to fit, I believe it stated the 8.5" ring gear was the size that fit.