hi all, i'm looking at an '03 Silverado 2500hd D/A cc/lb and am thinking about converting it to a 4x4. I'm likely going to do everything myself as I have quite a few tools and a good mechanic friend that has done this on an older Chevy. Anybody in here done this before?

Unless you plan on going SFA, Its most likly cheaper to buy a 4X4

im with rebel on that one

More than likely it would be cheaper to buy a new truck then to converter a used to 4x4

Yea, what they said. I know someone who did that once.........ONCE.(Fans of Johnny Dangerously will get that one.)

Obviously it would be cheaper to purchase a 4x4 truck, but not necessarily alot cheaper. All compareable trucks I've looked at were double the miles and several thousand more than this one. I understand that the HD 2x4s and 4x4s use the same frame and suspension and that the t-case would just slide right in (no disassembling of the tranny). Basically I would need the front axle, shaft to the front axle, both half-shafts, fasteners, the t-case (I'm thinking an NVG 261 if I can find one), manual t-case linkages, and I'm also thinking about using a Posi-Lock system. I'm not a huge fan of electronic stuff these days.

Considering that there would be no permanent modifications done, and that I own a 3 bay shop full of tools, hydraulic hoists and jacks, and work with a guy that is a mechanical genius, the biggest hang-up would finding parts. Obviously, if it's going to be 4k or more in parts it's definitely not worth my time or efforts. I do, however, have a business account with NAPA so I can get parts wholesale should I need any.

I know I sound crazy, but I'm bent on doing this. I've already found a wrecked HD and am researching it as we speak.....):h

I think it is totally possible to do. Your best bet would be to locate a wrecked 4x4 with a good front end and salvage that sell the rest of the truck off for cash to buy anything you may need for your project.

Not sure i would tackle it, but would like to know how it turns out.

Hey, if you're doing it for fun, or just for the experience, or maybe to be able to say that you built it yourself, then go for it. Just don't expect it to be cheaper than buying one that's already a 4X4. Be realistic about the project and you won't be disappointed.

Some issues to think about.....With the prices and deals of new trucks you would probably be better off buying new. Plus I think resale on a convert would be crap but I duno. Also there is the electrical side of things and intigrating that. The allison has a different tail shaft, that will need to be swaped, I dont know if that could be done in the vehicle or not since I'm not sure whats different. Talk to Mike L or one of the other smart guys on that.

If I were to do it as a cool project I would probably swap in a SFA just to be a cool/different project.

I'd have to go aftermarket for an SFA, though. That would be an easy $2000-$2500 am I right? Even after all is said and done however, I'll have an '03 with 40K (likely less on the front end) and will have saved a good $10K over a new one. Plus this truck already has a spray-in bedliner, Ranch-hand rear bumper, grille guard, and running boards. (theres another what? $1200?).

http://i5.photobucket.com/albums/y162/craq/coolchevy.jpg
http://i5.photobucket.com/albums/y162/craq/coolchevy2.jpg

it's a good virgin chevy at an awesome price. just gotta evaluate the logistics of converting to 4x4. SFA would be perfect for what I do for a living, but likely too expensive.

Take the parts off the one you have now, sale it and buy you a 4X4. You will save time, money and probably a little of your sanity. And once you install all of you goodies on the new one it will be just like you want it. :)

An aftermarket front Dana 60 is gonna cost more than $2500 (my Dynatrac was $5000 and that was 5 years ago), then you've got the springs and hangers, plus converting to crossover steering. The transfer case is not cheap, and will not bolt up to a 2wd tranny, so you're lookin' at another $1500-2000 for the t-case and adapter for the tranny. New driveshafts front and rear. You're looking at 7 grand, minimum, not counting labor. There is no way it is cost effective.

Just put posi-track on the rear and a winch on the front..... ;) and drive it!

If your looking for IFS there is a guy on here who is doing a SFA swap. You might want to contact him and get his IFS. I think his name is BIGBLOCKBILL not for sure. Somebody will correct me if I'm wrong. OR search for a SFA thread.

Rear section of Ally has to be changed and they are not plentifull. Probably have to buy a core and they are not plentifull.
mike

Rear section of Ally has to be changed and they are not plentifull. Probably have to buy a core and they are not plentifull.
mike

:exactly: not to mention drive shafts and such..
I know plenty of guys that did the conversion on older GM trucks (70's and 80's 1 tons to be exact)
A guy could do this project, but man it sounds like a big time headache...

No offense but this is one of those projects that if you have to ask you shouldnt be attempting......

I did this conversion ONCE. Never again. You can not believe the headaches and the money it will cost you.

I did this conversion ONCE. Never again. You can not believe the headaches and the money it will cost you.
what do you do the conversion to?

An aftermarket front Dana 60 is gonna cost more than $2500 (my Dynatrac was $5000 and that was 5 years ago), then you've got the springs and hangers, plus converting to crossover steering. The transfer case is not cheap, and will not bolt up to a 2wd tranny, so you're lookin' at another $1500-2000 for the t-case and adapter for the tranny. New driveshafts front and rear. You're looking at 7 grand, minimum, not counting labor. There is no way it is cost effective.
Figures. I'm not actually looking at getting all brand new parts. Like I said, I've spotted an '04 model with very low miles, so if they aren't damaged, there are two used shafts alone.

I was talking to a mechanic the other day who was trained in Indianapolis on the Allison 1000s. He're's what he said on this topic:


Actually, it would not be all that difficult to add 4wd to an HD as they use the same frame, torsion bar suspension, ride height and everything as the 2wd. The 2wd and 4wd HD’s even have the same ride height. If you pop the center-bearing cap off of the front wheels behind the hub cap on a late model 2wd HD you will also notice the hubs have spines in them for 4wd usage. GM did a lot of parts consolidation between 2wd’s and 4wd’s on the GMT800 platform. Adding a transfercase would be as easy as removing the tailshaft housing and sliding on a transfercase on then locating a 4wd drive shaft at a salvage yard.

In my opinion the 1999 and later trucks would be the easiest GM trucks ever built to convert to 2wd if you wanted to stick to the IFS stuff.

and on another instance,

When I went to Indianapolis for Allison 1000 Series training, they said the tails were the same as far as spline count and mainshaft length. There are some other differences in the Allison 1000 as the units built in Indianapolis have the SAE round bell housing and the units built in Baltimore have the GM design bell housing. Some have a PTO gear in the trans and others do not.

Please, I don't wanna see someone post the worn out saying "don't believe anything you hear on the 'net and only half of what you see". I'm not taking anything I read as gospel, but rather with a grain of salt and am getting as much advice and as many opinions as possible before I attempt this project.

For now, I think I will stick with IFS for obvious reasons. :)

Hey,

I remember seeing this type of conversion done in 4WHEEL&OFFROAD. A company in California did it, and I believe the cost was somewhere around $10K installed.

Keep us posted and take care.

Will

I'll give the other side of the picture.The SFA swap is not as expensive as it's cracked up to be if you have the right tools,a shop,and do it yourself.I have a buddy that has a 4x4 shop.He builds comp buggies. I was discussing it with him and his friends and they have done it to an 88-98 truck for around $1500.That was building their own brackets and getting and rebuilding a used D60. I plan to do a SFA swap on mine sometime because I dislike IFS -:t.If you don't go with a SFA,I would just buy a factory 4x4.

Hey,

Here is the link. I agree also, if you dont farm out too much work, and also plan it right, it should be fun, and not too costly.

Here is a link for some ideas. Good luck and keep us posted!!

http://www.offroadunlimited.com/

Take care,

Will