1984 Ford F250: 2WD to 4WD Conversion Guide

Converting a 1984 F250 from 2WD to 4WD is a big project, but definitely doable. Going with a Dana 44 straight axle is a solid choice — especially if you want a more straightforward and durable setup compared to the Twin-Traction Beam (TTB) alternative. Let’s break it down.

Why Choose a Dana 44 Solid Axle?

1. Simplicity: The solid axle with radius arms and coil springs is less complex than a TTB setup. That means fewer moving parts to maintain and replace.

2. Durability: Solid axles are generally more robust, which is a plus if you plan on doing any heavy-duty work or off-roading.

3. Aftermarket Support: A solid axle swap has a lot of community support and available parts, including lift kits and custom fabrication parts.

Steps for the Conversion

1. Front Axle Swap:

   • Remove the existing 2WD suspension and components.
   • Install the Dana 44 axle. You’ll need to ensure you have the proper brackets for mounting the radius arms and coil springs to your frame.
   • Make sure the axle is correctly aligned and centered.

2. Transfer Case Installation:

   • Swap out the 2WD transmission or modify it to accept a transfer case. A transmission with a removable tailshaft is ideal.
   • Install a transfer case compatible with your transmission. The NP205 or NP208 are common choices.

3. Driveline Modifications:

   • Fabricate or source new drive shafts for both the front and rear. Length and yoke compatibility will be crucial.
   • Ensure the U-joints are properly aligned to avoid vibrations.

4. Steering Adjustments:

   • Modify or replace the steering linkage to accommodate the new axle.
   • Consider a crossover steering setup if you’re looking to improve handling and reduce bump steer.

5. Brake System:

   • Adapt the brake lines for the new axle setup.
   • You may need a proportioning valve to balance the brake force between the front and rear.

Pros and Cons

• Pros: Improved off-road capability, increased durability, and a straightforward setup compared to TTB.
• Cons: Requires cutting and welding, driveline modifications, and potential challenges with legalities or inspections.

Potential Pitfalls

• Alignment: Proper alignment of the axle and radius arms is crucial. Improper setup can lead to handling issues.
• Parts Compatibility: Ensure all parts like the transfer case, drive shafts, and steering components are compatible with your setup.
• Budget: This swap isn’t cheap. Consider all costs, including unforeseen ones, before diving in.

If you’re looking for more detailed guidance, check out some resources on the Bullnose Ford subreddit or see if the Bullnose Garage channel has related videos. Good luck with the swap, and keep asking questions if you need more info!