Hello. I wanted to start a thread to share the 4x4 conversion and general build out of my 2009 E350. Technically I'm building this for a friend but for sake of conversation it's mine
. I'll try and post pictures as it goes and probably have a few questions along the way. Full disclosure in that I definitely should have done more research prior to jumping into this build but it sounded fun so we will just need to figure things out on the fly.
= 2009 E350, SWB, 6.8l V-10, around 160,000 km (O-Canada).
The suspension plan
= 2005+ Super duty front axle & radius arm, DIY radius arm brackets, track bar, lower coil mounts, 880s coil springs. Rear will get a DIY 4" shackle flip, maybe a lift block if necessary to level. Retain the stock rear axle along with some wheel spacers/adapters to convert to 8x170 BCD.
= I have a free 373 transfer-case so depending on how challenging setting up the electronics are (I did see there were a few posts on here about this) I may go this route. If not manual 371 all the way.
General Build Out. Van is going to be used as an "adventure rig" so it will not get a full on camper conversion but will receive some upgrades. 24" high roof, front & rear bumpers, ladders, roof rack, fender flares, the basic stuff.
Fuel tank. Completely caught me off guard that the fuel tank would occupy the same space as the transfer-case. However I believe the plan will now be to build a larger capacity tank to replace the factory tank in the same location. Along the same lines as the ones offered by TransferFlow.
Exhaust. I haven't seen others mention this but the drive side catalytic converter sure looks like it is right where the front drive shaft needs to be. Not sure if a 4x4 truck Y-pipe can be used or cut and weld the stock one to make everything fit. Status on this is TBD.
Not planning on re-inventing the wheel here and the build will rely heavily on the influence of others and their builds and components.