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2wd 02' burb to 4wd?

A

ACannell

1/2 ton status
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Apr 20, 2010
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Gardena California
Ok so call me crazy but here's my idea;
I have 91 4x4 3/4ton burb 350tbi(worn out) and a 4l80e/np241 set-up. I also have access to a partners 02' burb 3/4ton 2wd 6.0/4l80e. I love my 91' but the $ of upgrading the motor is substantial and the stock 02' has better output without touching it!
I am concidering swapping the tranny/transfercase out of the 91 into the 02' along with the sas set-up. Comfort and reliability to boot! This way I get 4wheel disc brakes with abs, nine airbags, functional air conditioning and a killer interior!
My other option is to do a 6.0 swap in the 91' and for go the creature comforts. I love this truck much more but the allure of the 02' is to much to resist yet.

I would love some input from anyone with any thoughts here. The misses loves the 'comfort' of the 02' as well.
Thanks for reading
 
ACannell said:
I am concidering swapping the tranny/transfercase out of the 91 into the 02' along with the sas set-up. Comfort and reliability to boot! This way I get 4wheel disc brakes with abs, nine airbags, functional air conditioning and a killer interior!

Thanks for reading
Click to expand...

You forgot to say the front axle from the old one to make it 4x4... This would eliminate your front ABS I would imagine....
 
Only problem would be figuring out how to reroute things. Might try and find a Ford front axle with the diff on the d-side already. Plus theirs are generally high pinion which ads strength.
More costly though.
 
I picked up a dodge D60 so Im in luck there. I am considering running the 2wd tranny and a divorced t-case right behind it. I have a 2000 4*4 pick-up, the 2002 2*4 burb and the 91' 4*4 burb to compare. This weekend I will be making plans as to whats the easiest or whats even feasible.
 
Ugh...look into the guts and issues with those Dodge "D60's". I assume it's a 94-02? They're not as strong as a standard D60 at all.
 
Ok so here is the D60.
PART951301448198605.jpg


So whats the selector here?
0529111653.jpg
 
That's the engagement dohickey that slides a little coupler between the two axle shafts. Known for issues and being a weak area. Since those don't have selectable hubs that's how they keep the whole diff from spinning all the time. 01-current they just got rid of it because the system was so problematic.
 
You can get a 4x4PosiLock cable actuated setup to replace the vacuum setup.

I heard you can use a 2000-2001 1 piece axle shaft in place of the whole setup and then fab a cover up. Still left with the weaker housing.

There is/are a kit(s) to put manual hubs and conventional bearings in place of the unit bearings they come with but it's not cheap at all.

Not trying to be rude but there's a reason you don't see many of those Dodge faux Dana 60's swapped under other trucks.
 
if i recall some guys swap on ford outer parts from a ball joint 60 to get locking hubs and live spindle. check pirare4x4 thats were i seen it i think.

also centeral axle disconect is the name for the device on pass side tube. heavy off road thay snap the tube section off there.

posi lock kit yes gets full man control of it. axle swap kit is needed to fix it cause the diff seal is now in the CAD section NOT in the pumkin like normal. so gear oil goes up to the CAD unit. replacement 1 peice shaft has the machined section to seal on the seal and keep gear oil in.

i know a guy who run 600hp cummins with 6 speed on his stock unit and 46" tires. then before he blew up more than few wheel bearing units converted to detroit locker/moser shafts/live spindle kit. but he had 02 so no CAD on his axle.

there was guy on pirate4x4 who did a 88-up 4wd conversion with a dodge front and low lift. he had lots of pics also.
 
Thank you both for the good info. I know it ain't the best axle in the world but its gota be better than a stock 10blt. I got the front 60 and a D70 with disc for $900. Not a bad deal to me.
 
http://www.4x4posi-lok.com/app_dodge.html
So here is the link I found for the disconnect kit. Now that I've looked at more info in regards to my D60 I see that maybe I should have passed and waited for a better deal. I'm still thinking for a mild trail usage and mainly a camping rig it won't be a big deal for me.

I have set a plan to have the stock four link junk cut off and the axle prepped for install within two weeks. In the mean time I threw my 33's on it for a wanta be look:)
33tiresNewWheels_06242011a.jpg
 
I am looking into removing my big rear windows and making a panel truck out of it. Has any body seen this done before? The curvature towards the top of the windows is such that I'm nervous about forming sheet metal to match the curves. Any ideas?
 
so make it look like an avalanche??? Seems like alot to do IMO. would be unique though.

avalanche.jpg
 
No, panel truck means taking the windows out and replacing them with sheet metal.
 
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