sorry for the poor pics. there off my LG Envy phone (2.0 mega pixels)
first start by removing the pro-comp lift spindles

removed


i had to fab a third bracket on the left frame rail. the first try was in the wrong place as you can see

next install front axle in the 2 factory mounting brackets then bolt to the third bracket


next instal both CV shafts

next install both knuckles and wheel bearings


next install 2 new raybestos 12 inch brake rotors



this is where i got into another project, replacing a front axle U joint on a jeep.after fixing the jeep i started on the rear of the truck, removing the AAL's, didnt get any pics of that.

the finished (lowered) product


as soon as i can source a transfer case i'll start the transmission conversion.

 

heres the shot of the doner parts (thanks erv)

 

so far i have around 150 in used parts, 50 for the 2 rotors.
i have 2 transmission options at the moment, first is replacing the output shaft and housing for around 250, (i have a friend that owns a transmission parts warehouse) but that will requier total transmission dissassembly. second option is a new take-out unit from a 2003 4x4 5R44E for $450.00 from the same guy. (its good to know people!)

i'm thinking the later of the two is the way i'll go, once i get the trans and Tcase it should be a one day project.

 

still cheaper then factory 4x4. my truck was $13,500 new. adding 4x4 would have made it almost 18 grand

 

ok new update. seems the ABS pump and module are diferent. the 2x4 unit does not like the 4x4 front speed sensors. i got a 4x4 unit cheap from a local yard and will be installing it within the next few days. pics will folow.

 

no brake problem. just a steady ABS light.

 

got the 4x4 ABS pump-module installed and now a new problem, seems the instrament cluster does not like the new ABS unit!
going into to ford next week i hope for a "cluster re-flash"

the tech said he could flash it any way i want, so i think i'll have him fix my speedo for the larger tires and flash it for a manual transfer case.

 

a 4x4 cluster would work BUT it would need to be out of a edge 3.0 4x4, the local yards want 75 for one, i can get my entire truck (cluster/pcm) reflashed any way i want it for 85 and wont have to remove anything.

 

heres a few teaser pics. havent got all the parts yet, tomorrow i will pick up the internal trans stuff!
tailshaft housing (thanks chuck at CTS transmission) FREEBEE!


4x4 tailshaft (thanks again chuck) FREEBEE!

92 explorer BW1354 MANUAL SHIFT transfer case $200.00


and a pair of front driveshafts, $50.00


i'll post more pics of the rest of the parts tomorrow. by mid july the deed will be done!!!!

 

oh and one more of my new tool box!

 

yeah i noticed that after i got the first one, always good to have spare parts anyway!!

 

i got a case (look close in the one pic) with very little inside it lol!

complete cores for my truck are impossiable to come by around here and i didn't have 600 for a used one so i will just take mine apart. easy enough!

 

got more stuff today

rear driveshaft

shift kit, most of it is already installed.

gasket and seal kit




filter

messy workbench

all i need now is fluid

 

sticking with IFS because its cheaper and easer to repair plus i drive it everyday, thus i dont have time to have it down for any length of time.
on the flip side of that if i do ever decide to do a sas i am already setup to "use" the front axle!

 

the deed is done!

first remove the driveshaft, exhaust and skid plate then drain the trans by dissconnecting a trans line and starting the truck untill no fluid comes out

next remove the dipstick tube and vent tube

next unhook all plugs and lines


next unbolt all bell housing bolts and remove crossmember

next remove transmission




i'll post the internal pics tomorrow but heres a teaser

 

first remove the pan and tailshaft housing



next remove the filter and valve body



next remove the bellhousing/pump



next remove all internal parts keeping them in order



then at last you have gotten to the little snap ring that holds the output shaft in


then remove the snap ring and enjoy the moment when you have the the old shaft out!
DSC01835.jpg?t=1180882916

now install 4x4 output shaft and snap ring


now reinstall all internal parts


now install inputshaft and bellhousing/pump

new 4x4 tailshaft housing



now reinstall the valvebody

and a new 4x4 filter

next the 4x4 pan (4x2 is different and not as deep)

then adjust the bands

next stand back have a miller lite and enjoy your work



tomorrow or the next day i will start putting the truck back together!

 

got is somewhat back together today. having a front driveshaft problem, one is to short one is to long. i'll adress this problem tomorrow






other then that everything works