1996 Ford Cargo build question….

1cambo

Active member
I recently bought this truck because it was super cheap,low miles, has a 12 valve Cummins and 6 speed Eaton manual transmission . Also of importance, truck has air brakes!
Questions are as follows, (1)-has anyone built a cab crawl through on a cab over design and if so please share what you did.
(2)- any one convert a medium duty truck to 4x4 and if so can you give advice/share what you did?
Thanks!
 

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Third

Member
I've got some shots of crawl throughs I've been saving until I do my LMTV. Most affix the tunnel to the habitat and collar the cab connection, some do the reverse. And on trucks with a lot of frame twist off-road, some mount the tunnel to the frame and actually collar both the cab and the habitat sides.

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1cambo

Active member
Thanks!
I really want to convert it to 4x4 and have a line on some ex military parts from a MAN 8x8.
Anyone have any suggestions on where to source larger axles ( read:airbrake) and an air shift tcase?
or should I save myself the $ and hassle and just get a rear locker?
we want to be able drive down some of the beaches and I am a wee bit scared of doing that with a truck this size without 4x4.
thoughts?
 

shortbus4x4

Expedition Leader
My guess is that if you attempt to switch over to air brakes, you will be putting A LOT of time, money, and reverse engineering into a vehicle that will get you laughed out of ANY .gov inspection station. Chances are they will demand the truck be put on a "low-boy" and and never to be used on a public road again.
Besides that, hydraulic over hydraulic brake systems work GREAT and are much easier to maintain (especially dual systems). I didn't like the idea of both my steering and brake assist being lost if the power steering pump failed so I split the system by adding another pump/ pulley/ belt for the brakes. "baby food" compared to re-plumbing a truck/ motor for air!

Your best bet is to stick with the correct "sized" driveline components when reconfiguring your truck to 4X4 ($x$)! But remember that you will battling some really challenging alignment issues. Most professional conversion houses "Z" the frame (cutting the front of the frame off the back and stacking it on top of the rear frame), thus buying the space for the transfer case and front axle under the engine.

Honestly, unless you have the facilities (like I-beam overhead gantry), tooling (like a way to fixture the frame on a flat/ level/ square surface), "top-shelf" 3D modelling software, AND WAD OF MONEY that you will most likely be wasting... I'd just put a locker in the rear axle, super-single wheels/ tires, a big stack of Bengy's in the "tractor fund" and go camping!
This, a rear diff lock, good tires, a stout snatch strap and some $$ in the tractor fund will be many many times cheaper than a 4x4 conversion.
 

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