Converting 6.9 diesel to 4x4

[johnboy]

Hello everybody. I found this site a couple of days ago and I am totally hooked. What a treasure chest of info. I'm lookin for a little bit of advice/help with my project. I have an '86 e-250 6.9 diesel that I am currently looking for parts to make a 4x4. My thoughts were dana 60 front end(this rig will be used for hauling, work, and as a recreational camper)and an np205 transfercase. The van currently has a c6 transmission and I have a wild idea of trying to find an allison tranny out of a school bus. I'm wondering wether anyone knows anything specific about how these parts might line up with eachother and or any other basics about this particular build.
Glad to be a member.
Sorry for the stupid thread title
should say CONVERTING 6.9 DIESEL TO 4x4
couldn't figure out how to change it

[ujoint]

Welcome to the portal! --- For the 4x4 conversion, you'll have to make everything custom, or find an existing 75-91 Ford 4x4 van and swap the parts over. ---- I'm not sure about the Allison tranny swap, you may be paving new ground on that one!

[ntsqd]

If the Allisons came behind the 6.9 or the 7.3 engines then one of those should bolt up. The real issue would be clearances around it and building a cross-member.

I would look for a divorced 205 as that will make any trans changes just a drive-shaft mod instead of a bunch of adapter fabrication.

[johnboy]

Wow that was quick. Thanks
My plan is to find the parts out of a f-350 4x4 probably from the eighties and rebuilding the axle and transfercase. I'm sure a project like this is gonna take alot of cutting and welding. Luckily I've got a machinest I can trade carpentry work with. As far as the allison goes that might be the easiest idea to just use a divorced transfercase. thankx

[wanderer-rrorc]

i would suggest www.oilburners.net for tech...

it is possible for the swap...

the ford 6.9/7.3's have an adapter to the diesel trans...the adapter I beleive is due to the diesels standard pattern being an industrial equipment setup...

it IS possible to use a 460 gasser trans..but the first gear is usually higher...and you have to drill diffrent holes..but its doable..

I would suggest the donor...but the parts can be sourced....not sure about the allison...but talk to campbell enterprizes (the guys that build race buggies) they can custom build you any adapter you want...but if the allison needs a computer for anypart it will need to be a stand alone unit..

my 6.9 is turbo'd and a C6...I dont even worry about the tranny after some of the things I have pulled...an overdrive (ranger/gearvendor) would help but only does the rear drive....but with a divorced case you would get OD for both...A divorced 205 would be BULLETPROOF...(should be...its damnear 3/4 in thick and weighs over 150lbs!)

it is TOTALY doable...not a weekend project...but in a week...you gotta have shafts made or at least make the mounts.

when I was going to convert mine I had a 44 8lug...and was planning on a ZF5/1356 out of a gasser for the 5th gear and keepin the drive/tranny lenght down to less than 8ft!

[ujoint]

The problem with a divorced t-case on a van is that the fuel tank is the way.

[haven]

Welcome to ExPo, johnboy. Remember, we'll need to see photos of your project!

I fixed the thread title for you.

Chip Haven

[johnboy]

Thanks for the good ideas. My tank will probably be in the way no matter how I hook up a transfercase. It's also the one that houses my WVO so I am probably gonna need to put a custom tank on the other side of the driveshaft.
I am just waiting for a nice day to take some pics of Gary(my van)so I can introduce him to you guys. I might be waiting on weather for awhile cause I live in Seattle.

[T.Low]

Welcome to Expo, neighbor, and fellow van enthusiast.

Where will you take your van once the 4x4 conversion is done?

[johnboy]

There is a good chance that I will be moving to alaska for a couple of years in a year or so. In the meantime I've been thinking about a trip to copper canyon in Mexico. I'm really looking for it to handle better in deep snow because thats when I really wanna drive deep into the cascades for some skiing.

[ntsqd]

The problem with a divorced t-case on a van is that the fuel tank is the way.
Easier to move, modify, or build a new one than to build a bunch of one-off precision adapter parts.

I have built a divorced transfer case drive shaft that consisted of no tube what-so-ever. It was a slip-yoke to a UJ to a flange to a modified mating flange to a UJ to flange. This all fit between a Toyota 4A-GE's 5 speed and a Samurai transfer case in a SWB Samurai. The owner did end up mounting the trans and transfer case as a unit, which then was rubber mounted to the chassis. ~120 HP in a nearly stock weight Sami is interesting......

[Mike S]

I had an '83 Ford F250 HD with the 6.9L engine. It had a BW T-19 4 speed manual tranny and two speed 4WD Tcase with dana 60s. I would think that a wrecking yard could provide a complete factory 4X4 drive train for your van. This is a very good engine and drive train combination.

[ujoint]

Easier to move, modify, or build a new one than to build a bunch of one-off precision adapter parts.[/i]

No custom parts will be needed, it can all be sourced from a scrap yard or from Ford direct. You're talking about the t-case, right?

[johnboy]

I think I found the donor truck on cr.
It's an 89 f-350 4x4 with dana 60 front axle, 7.3 idi diesel, a 5 speed tranny(yeah!) and 411 gea ratio.
The truck is already leaf sprung and it had the tranny rebuilt 10,000 miles ago.
This sounds to good to be true.
Please somebody tell me that this transmission is gonna bolt onto my 6.9 engine.

[Mike S]

I think I found the donor truck on cr.
It's an 89 f-350 4x4 with dana 60 front axle, 7.3 idi diesel, a 5 speed tranny(yeah!) and 411 gea ratio.
The truck is already leaf sprung and it had the tranny rebuilt 10,000 miles ago.
This sounds to good to be true.
Please somebody tell me that this transmission is gonna bolt onto my 6.9 engine.

Thew 6.9 is the predecessor to the 7.3 and is closely related. They are both by International, and I believe they share the same block.

[wanderer-rrorc]

Thew 6.9 is the predecessor to the 7.3 and is closely related. They are both by International, and I believe they share the same block.

yup...it WILL bolt to it.....

theres many people that have gotten rid of the dual mass flywheel (DMF)...check oilburners.net for writeups...

oh...and post some pictures!!

[ntsqd]

Why not just put the 7.3L in the van?

[johnboy]

The donor truck has a blown up 7.3.
My van only has 150,000 or so and the engine runs really sweet. I've replaced almost all the goodies( alternator, fuel pump, vacuum pump.......).
Sorry about pics but I sent my camera in to get fixed and it should be back any day now.
Wouldn't you know as soon as I sent the camera out the weather turned really nice in seattle and I've missed a bunch of sunny days to fire off pics.

[johnboy]

Well bad news. I didn't jump on the truck from cl quick enough and the guy sold it out from under me while I was on the way to his house.:(
Next time I'll just show up for my axle 2 hours early.
Let the search continue.
I finally got my camera back and shot a couple pics of my van but I can't figure out how to post them yet, but I'll keep working on it.

[Rot Box]

For future reference any transmission that came behind a 7.3 IDI will bolt up to the 6.9. They are essentially the same engine aside from displacement and head bolt size. The 6.9's didn't suffer from block worm so I'd say they are the better of the two. The 460 and other gasoline powered trucks had a different bellhousing pattern so they will not bolt right up. If you can find another truck with the ZF 5 speed that will ultimately be your best bet for a transmission and transfer case. The 85.5-97 Dana 60's are all the same for the most part...

Sounds like a fun project and what a great platform to start with :wings:

[johnboy]

Thanks RotBox
Are you aware of any automatic transmissions with an overdrive that will bolt to these motors. I would love to have the manual but I don't wanna bother with the slave cylinder and clutch pedal. An automatic seems like it could be done in very little time.
What about something that came behind a powerstroke.

[Rot Box]

Thanks RotBox
Are you aware of any automatic transmissions with an overdrive that will bolt to these motors. I would love to have the manual but I don't wanna bother with the slave cylinder and clutch pedal. An automatic seems like it could be done in very little time.
What about something that came behind a powerstroke.

Sorry for the late reply :(

Any four speed auto from an 89-94 IDI Diesel will work for sure. These transmissions are known as the E4OD 4speed and they seem to be pretty reliable/strong once the factory torque converter is upgraded to an aftermarket unit. I don't know a whole lot of specifics about them other than they do have an electronic overdrive so you would need to find a donor truck/van with the computer and harness. Just like the manual transmissions they must be from a diesel and not a gas engine :elkgrin: Hope this helps,

Andrew

[johnboy]

Hey thanks for the reply.
No worries about the time issue.
I've been on some road trips and my computer has been down.

[johnboy]

Here are some pics finally I hope

[johnboy]

So I just made the score I've been looking for.
I bought a 1976 e-250 pathfinder 4x4 chassis.
It's only a dana 44 but oh well.coil sprung.
Looks like a pretty easy bolt on but I'm gonna need to refurbish some of the parts.
Does anyone know a source for pathfinder parts?

Oh yeah. I also just bought a zf5 transmission and a borg worner transfercase out of an 88 f350. So if anyone knows anywhere to acquire a clutch pedal that fits a E-series van please let me know.

Still trying to get some of my pics to post. Not sure what I'm doing wrong.

[Herbie]

Does anyone know a source for pathfinder parts?


Pathfinder Vans (http://www.pathfinder-vans.com/html/about_us.html)

[johnboy]

Thanks Herbie thats awsome.

[johnboy]

Finally got some pictures.................
http://i891.photobucket.com/albums/ac119/buddyotis/March2010120.jpg
http://i891.photobucket.com/albums/ac119/buddyotis/March2010121.jpg
http://i891.photobucket.com/albums/ac119/buddyotis/March2010124.jpg

http://i891.photobucket.com/albums/ac119/buddyotis/March2010298.jpg

http://i891.photobucket.com/albums/ac119/buddyotis/March2010292.jpg
heres my new zf5
http://i891.photobucket.com/albums/ac119/buddyotis/March2010303.jpg