Bullnose Bill Answer
by Ed

How can I convert my 1984 F250 2WD with Dana 61 to a 4WD system?

Bullnose Bill explaining the 1984 F250 2WD to 4WD conversion process.

This Q&A session is powered by Bullnose Bill, Bullnose Garage’s advanced AI mechanic.
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Bill says:

Converting your 1984 F250 from 2WD to 4WD is quite the project! It’s a doable endeavor if you’ve got the time, tools, and determination. Let’s break down the process and the main components you’ll need to tackle.

Key Components Needed

  1. Front Axle:

    • You’ll need a solid Dana 44 or Dana 60 front axle, depending on the weight and intended use of your truck. The Dana 60 is heavier duty and might be preferable, especially for an F250.
    • Ensure you get the necessary radius arms, coil springs, and brackets.

  2. Transfer Case:

    • The NP205 is a solid choice for durability. You’ll need the appropriate transfer case adapter to mate with your existing T18 transmission.
    • Double-check your driveshaft lengths, as they will likely need to be custom made or sourced.

  3. Driveshafts:

    • Front and rear driveshafts will need adjusting or replacing to fit the new setup. Be prepared to have custom ones made or modified.

  4. Suspension and Steering:

    • 4WD conversion may require modifications to the suspension, such as installing leaf springs or converting to coil springs, depending on your front axle choice.
    • Steering components will need upgrading to handle the 4WD setup, like a steering box compatible with 4WD and potential linkages.

  5. Crossmember and Mounts:

    • Ensure you have the right crossmember and mounts for the transfer case. Fabrication might be necessary.

Steps for Conversion

  1. Planning and Research:

    • Gather parts and research thoroughly. Look for a donor truck if possible, as it can provide many of the necessary components in one go.

  2. Front Axle Installation:

    • Remove the existing 2WD front suspension and install the 4WD front axle. This might involve welding new brackets and modifying the frame slightly.

  3. Transfer Case and Transmission:

    • Remove the existing transmission if needed to install the transfer case adapter. Install the transfer case and ensure proper alignment and support.

  4. Driveshafts and Linkages:

    • Install or modify driveshafts to fit the new setup. Ensure the angles are correct to avoid vibrations.

  5. Steering and Brakes:

    • Update the steering linkages and ensure brakes are configured for the new axle setup. Consider upgrading to heavy-duty brakes if not already done.

  6. Testing and Adjusting:

    • Test drive and check for any unusual noises or behaviors. Adjust as necessary.

Pro Tips

  • Donor Truck: Finding a similar generation 4WD truck as a donor can save you time and hassle, especially for components like axles, transfer case, and linkages.

  • Documentation: Keep track of what changes you make and any custom work done for future reference or troubleshooting.

  • Community Resources: The Bullnose Ford subreddit is a great place to connect with others who may have tackled similar projects.

Converting to 4WD is a substantial project but can be highly rewarding, enhancing the capability and value of your truck. Good luck, and enjoy the process! If you need more detailed guidance along the way, feel free to ask.

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User:

Can a complete front HP Dana 44 with radius arms and steering linkage be installed on my 84 F250 2WD?

Bill avatar

Bill:

Converting your 1984 F250 from 2WD to 4WD isn’t exactly a simple bolt-on affair, but it’s definitely doable with the right parts and some elbow grease. Let’s dive into it.

Key Components for the Swap

  1. Front Axle: The high-pinion (HP) Dana 44 is a good choice for the front axle. However, it’s important to ensure you have the entire setup, including radius arms, coil springs, and steering linkage.

  2. Radius Arms and Mounts: If you’re going with the Dana 44 that comes with radius arms, you’ll need to install radius arm mounts to your frame. These aren’t typically present on a 2WD frame, so you’ll have to fabricate or source mounts that fit your specific setup.

  3. Crossmember Modifications: Some crossmember modifications may be necessary to clear the differential. Make sure to check for any clearance issues with your oil pan and engine crossmember.

  4. Drivetrain Considerations: Since you’ve got the T18 transmission, you’ll need a transfer case compatible with it. The NP205 is a popular choice due to its strength and gear-driven design. You’ll need the appropriate adapter for your T18.

  5. Driveshafts: Custom driveshafts will likely be needed to accommodate the new axle and transfer case setup.

  6. Steering Linkage: Ensure that your steering linkage matches up with the new axle setup. You may need to fabricate or source parts to ensure everything aligns correctly.

Potential Pitfalls

  • Alignment Issues: Proper alignment of the axle and radius arms is crucial for handling and tire wear. Double-check your measurements and mounts.

  • Brake Lines and Hoses: These will likely need extending or rerouting to accommodate the new axle setup.

  • Gear Ratios: Make sure your front and rear axle gear ratios match to avoid drivetrain binding.

Pro Tips

  • Sourcing Parts: Parts trucks or junkyards might have the axle and components you need. These can be cost-effective if you’re working on a budget.

  • Online Communities: Check out the Bullnose Ford subreddit (reddit.com/r/bullnoseford) for advice and experiences from folks who might have tackled similar projects.

Converting a 2WD to 4WD is a big project but rewarding if you’re looking to improve your truck’s capability. If you need more detailed guidance, there may be a related video on the Bullnose Garage YouTube channel that could help. Good luck, and don’t hesitate to reach out if more questions pop up!

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User:

Do you have a video link that covers the 1984 F250 2WD to 4WD swap?

Bill avatar

Bill:

I don’t have direct access to link specific videos, but the Bullnose Garage YouTube channel is a fantastic resource. I recommend heading over there and searching for terms like "2WD to 4WD conversion" or "Dana 44 swap" related to Bullnose Ford trucks. There’s a good chance you’ll find some detailed guidance or a relevant video covering aspects of the swap. Plus, it’s always worth checking out their playlists for related topics. Happy wrenching!

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User:

I appreciate your help.

Bill avatar

Bill:

You’re welcome! If you have any more questions or need further assistance, feel free to ask. Enjoy working on your Bullnose, and good luck with the conversion!

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User:

Will a Dana 44 TTB front end fit in place of the 2WD twin eye beam arms using the current cross member?

Bill avatar

Bill:

Swapping a Dana 44 Twin-Traction Beam (TTB) front end into a 2WD F250 using the existing crossmember isn’t a straightforward bolt-in swap. Here’s what you need to consider:

Key Considerations

  1. Crossmember Compatibility: The 2WD twin I-beam setup has a different crossmember design compared to the 4WD TTB setup. You’d need to modify or replace the crossmember to accommodate the Dana 44 TTB. This often involves cutting, welding, and fabricating new mounts.

  2. Radius Arm Brackets: The TTB system uses different radius arm brackets than the 2WD beams. You’ll need to source or fabricate these brackets and ensure they’re properly mounted to the frame.

  3. Coil Springs and Mounts: The coil springs and their mounts will differ between the 2WD and 4WD setups. You’ll need to make sure you have the correct spring perches and mounts for the TTB system.

  4. Drivetrain Adjustments: If this swap is part of a 4WD conversion, don’t forget to address the transfer case and driveshafts, as well as ensuring matched gear ratios between the front and rear axles.

  5. Steering Components: The steering linkage for the TTB will be different. You’ll need to adapt or replace these to work with your current steering setup.

Potential Pitfalls

  • Frame Modifications: Be prepared for some significant frame work to mount everything securely. This isn’t a task for the faint of heart and might require professional fabrication assistance.

  • Alignment Challenges: Make sure to set up the front end alignment correctly after the swap to avoid handling issues.

Pro Tips

  • Donor Vehicles: Consider finding a donor truck with a complete TTB setup to simplify sourcing parts.

  • Measurement and Planning: Take precise measurements and plan your modifications to avoid any surprises during the swap.

Converting from a 2WD to a TTB 4WD system can be complex, but with careful planning and the right resources, it’s achievable. If you need more visual guidance, I’d check out the Bullnose Garage YouTube channel for similar projects—they might have a video that helps. Best of luck!

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User:

Thank you for your assistance.

Bill avatar

Bill:

You’re welcome! If you have any more questions or run into any issues, feel free to reach out. Enjoy the project and keep those wheels turning!

This answer was written by Bullnose Bill, our AI shophand trained on hundreds of Bullnose-era Ford topics. He knows his way around old Ford Trucks.

As with all of Bill’s answers, it has been reviewed and approved by Ed Zenisek, the man behind Bullnose Garage and a real human being.

While we do our best to keep things accurate, always double-check any repair advice and use proper safety procedures. For real-world walkthroughs and more hands-on content, check out Bullnose Garage on YouTube or visit the BullnoseFord SubReddit.

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