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I think I'd go with one a couple years old and save a chunk of change to spend on mods... https://www.ebay.com/itm/2015-Chevrolet-Express/113112985040?hash=item1a560f2dd0:g:BF8AAOSwotFbNUfH&vxp=mtr My guess is that that one could be had for a good bit less..

I think you're only option is to replace it. A manual shift NP241 would probably be the easiest swap.

Chassis is sold but the front clip is still available. Includes full cooling stack, front bumper, and inner fender structure

I didn't bother with a kit, I just bought bags and some prefab mount plates and welded it all in on my own. My hope is that low pressure will be all that's needed most of the time.

I would do just air bags first, my bet is that you'll get all of what you're looking for with just that. I'm going to run stock 2500 springs on my build (a lot heavier than you guys are) with air lift dominator bags to tune for load/ride height and sway control.

Complete rolling chassis with powertrain for a 96-02 Chevy Express or GMC Savana: https://sandiego.craigslist.org/nsd/pts/d/express-savana-rolling/6677654009.html Complete front clip for the same: https://sandiego.craigslist.org/nsd/pts/d/1996-to-2002-chevy-express/6678289497.html

Yes, using a BCM(or having yours reprogrammed to match) from a matching (optioned) donor would be required, the 4Low switch signal from the Transfer-case goes to the BCM, it then sends that signal (via Class2 or GMlowspeed data depending on what year van you have) to the ECM. It's tough to deal...

With the tuning from a pickup equipped with a manual shift t-case you can remedy the 4Lo shifting issue. The ECM/TCM needs to see the 4Lo signal coming in via the data bus and it will rescale the shift points based on the 2.72 ratio.

The 241OR is for rockcrawling, I run one in my rockcrawler and love it...I would never consider it for a van. I'm building a 4x4 express van right now and using the NV263 (also 2.72) which is plenty of low end for anything I'll ever do.

I'm not a ford guy but you are going to need to add a lot more detail if you want useful feedback. What year/model ambo do you have? what year/model donors are you considering? what is your level of fabrication skill/capability? what kind of budget are you working with?

It's usually a blown out spring/shackle bushing that allows the spring to shift and do that. It's very common for the shackle bushings to fail and then the shackles to crack/break.

The 05 and up SD Dana 60 is the best supported for this (DIY) swap, but, it's a lot of fab work, you will either have to be willing and able to do it, or, willing to write a good size check to have it done. I had very specific desires for my build that drove me to using the late mode Dodge AAM...

I've been playing with the idea of customizing the swivel to make the center of rotation to be to the rear/inboard to get the seat to shift immediately away from the door and steering wheel...just throwing spaghetti at the wall at this point..

155" all the way!

I'd think that they would have used suburban/blazer 4x4 front springs from the same period; and those are really flat to start with so no surprise they would sag under

I don't think you can do it with a stock seat, the steering wheel is tough to avoid, if you try and move back to create clearance you have the b-pillar moulding/structure to deal with...I'd like to crack this nut as well..

7 years certainly qualifies as "a while"

Yes, obviously whatever you remove in the way of structure you'd need to replace/relocate/increase. The stock winches fill with road grit and lock up either going down or coming up, it's just a matter of when... there's 37" of room between the frame rails so you can do quite a bit if you aren't...

The form and centerline of the original carrier are the problem (or I should say are the other problems, the stock winch is junk) the space between the frame rails will support a 35" tire, but, you'd have to cut out/modify/fab new holder in it's place. I just cut mine out and will use that space...

https://chevroletforum.com/forum/express-g-series-vans-30/ is probably the the best for gas vans, DieselPlace has a good forum for Duramax powered vans.