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Old 04-23-2009, 10:20 PM   #1
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Just Finished My E350 4x4 Conversion

Hello all,

This is my first post on this forum. I am just excited to finish my 4x4 conversion on my 2001 extended E350 V10. I bought the wagon in January with 29xxx miles on it from a fella in Colorado Springs for $7300. Bought 2006 F350 junk yard axles, and went to work. I have been driving it for about 3 weeks now, still tweaking the little things. I have about 11K in it now and absolutly love it! Here is my build list:

06 F350 front axle (Super 60). used F350 coils (3" taller than van) and F350 radius arms, fabbed custom brackes to attach to frame (PITA!). Used all of the F's steering links and track bar, built custom track bar frame mount. Installed 00-04 Super Duty ABS sensors for compatiblity with van.

06 F350 rear axle (Sterling 10.5"), had to move perches out 2" per side. Used all F e-brake hardware (plug-n-play!). added 3" lift blocks (perches were .5" taller than van for total of 3.5"). VSS sensor swapped from van's axle into the Sterling, ABS works!

02 NP271 manual shift t-case. 1990 Bronco shifter with modified handle for van. Bought a spacer from Quigley so I didn't have to tear the tranny apart. I redrilled the pattern so I could clock up the t-case for more ground clearance. I had to attach extensions to the crossmember to drop it 2.5".

Custom front and rear drive shafts. 1350 CV front and 1410 rear.

Hope to post pics soon!

I am following my long time buddy, dsw4x4, in the building of a pop top using a "raised roof" fiberglass top this fall. See link here:

viewtopic.php?f=24&t=2327

Thanks for the interest,
TurboStew
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Old 04-24-2009, 09:59 AM   #2
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Re: Just Finished My E350 4x4 Conversion

Welcome to the forum TurboStew! Congrats on building your own 4x4 van, that takes some fabrication skills and talent. I'm very interested in learning how you re-drilled the transfer case so it didn't hang down so far below the frame rails. Was it the t-case or the Quigley adapter that was modified?
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Old 04-24-2009, 11:27 AM   #3
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Re: Just Finished My E350 4x4 Conversion

Nice job getting all the sensors to work out. Nice job on the whole thing!
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Old 05-05-2009, 09:04 PM   #4
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Re: Just Finished My E350 4x4 Conversion

Thanks all for the warm welcome! Sorry for the long delay. Still no pics .

I redrilled the Quigley adapter. I have a program for my CNC Bridgeport Mill to redrill the 6 bolt pattern. I'll shoot a pic of the t-case.

I am just about to pull the trigger on a set of 285-75-17 (34s) Toyo ATs. I moved the front axle about 1.5 inches forward of the stock location. I think it will clear with the 3.5 inches of lift and no fender trimming.
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Old 05-14-2009, 12:06 AM   #5
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Re: Just Finished My E350 4x4 Conversion

Finally Pics!



























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Old 05-16-2009, 10:02 AM   #6
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Re: Just Finished My E350 4x4 Conversion

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Old 05-16-2009, 04:00 PM   #7
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Re: Just Finished My E350 4x4 Conversion

Great job on the conversion!! Looks awesome!!
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Old 05-17-2009, 11:58 PM   #8
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Re: Just Finished My E350 4x4 Conversion

Thanks UJOINT, same to ya! I have come across your posts many times in my research.
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Old 05-18-2009, 12:24 AM   #9
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Re: Just Finished My E350 4x4 Conversion

Looks good... I have to question having the brake lines outside the shocks on the front... I suppose they could get damaged anywhere, but they seem a lot more vunerable to catching, snags, and getting mashed against the shock in that position.
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Old 05-20-2009, 06:02 AM   #10
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Re: Just Finished My E350 4x4 Conversion

In regards to the brake lines, the clearance is very similar to a 2001 F250 (I used 2001 f250 lines by recommendation of Craig at Salem Kroger). The shock/spring clearance is not a problem at all, but the line is a little close to the tire for my liking, I have been monitoring the situation closely, no rubs yet.

No thrashing on the ABS wires yet, still need to clean up the routing and tie points.
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