2002 Chevy Express 4x4 conversion

[dreamroad]

Hi guys!

I am new to American vans but not new to 4x4 vehicles at all. I have been modifying Toyotas for many years, I can TIG weld, I can fabricate suspension components etc. I want to start a 4x4 build on a 2002 Chevy Express high-top van which I currently use as a campervan. I am new to GM equipment so I need guidance on which things to buy...

I have the van with 5.7 engine, 89K on the clock. Runs smooth. I am planning to use it for overlanding so there is no need to solid axle swap.

Which things should I buy and which ones are as close to a direct fit as possible?

1. Transfer case that is almost bolt on
2. Shorter driveshaft for the rear
3. Driveshaft for the front
4. Steering knuckles
5. Front differential
6. Front axles
7. Front control arms

Plus any other components which are cheaper to buy from the junkyard than fabricate from zero: crossmembers, suspension arms etc.

The Express is based on the GMT600 platform (https://en.wikipedia.org/wiki/GM_GMT_platform) which seems unique but I am sure that parts from Sierra, Silverado, Tahoe, Suburban, Yukon etc should be a direct fit.

I would like to start the build as soon as possible but just need people to help me with the shopping list. Once I have all the things on my floor I will know how to connect them.

Thanks.

 

[RVflyfish]

You might give Jeremy at WeldTec a call. He's the man for 4x4'ing Chevy vans. You may have seen his SEMA builds on here.

 

[Len.Barron]

There is some interchangeable front parts with the early 90's pickups/suburbans, one of those would likely be a good donor vehicle.

 

[Weldtec Designs]

Unfortunately for this year i know very little other then i hate the suspension. It is very difficult to do much in order to keep IFS. Our products work with the 2003 and newer models.

 

[Len.Barron]

i know very little other then i hate the suspension

agreed...I was glad to see the old chassis loaded up and gone when I did my conversion..

 

[dreamroad]

Thanks for the information. But let's start step by step. What transfer case will fit? What knuckles? What front diff? I need to start with the big items and the small ones will follow

 

[Len.Barron]

what's your intended use? do you want to lift it at all or run larger tires? do you want fulltime AWD or part time 4x4? You're not going to make the truck/suburban 4x4 IFS fit that frame so you are going to be looking at solid axle swap. You would be miles ahead to buy an 03-up AWD van and sell yours..

 

[vintageracer]

If you must have a 4WD GM van so buy one already converted to 4WD and start your modifications from there!

 

[dreamroad]

The thing is that I don't see how it would be much cheaper. The conversion vans I see here cost well over $15K for the AWD model. Usually closer to $20K. I got my 2002 chevy for $3800 (95K ODO, zero rust from NV) and I have made a campervan conversion. How much would a transfer case be? even if it's $1000, even if the axle is $1000, the driveshafts and new brake pads, rotos $1000, Even if I want to change the rear diff (a bit to noisy) for another $1000 and even if I add another $2000 for bits and pieces...

I get $6000 plus the cost of my van around $4000 it totals $10K. Still half the price of an AWD van in the same condition (zero rust, low mileage).

 

[dreamroad]

Oh, and I need part time AWD. I use my van to travel with kids and need 4x4 when I'm stuck. No need to have permanent 4x4 if it makes the price lower for me...

 

[45Kevin]

A guy on this forum added a part time TC to his AWD express. I think it was an NP205. It bolted right on to his 4L60. I'll try and find the thread but you could probably search it yourself.

The AWD frame is different from the RWD van.
If you don't mind modifying the frame you might be able to get a 'burb or GM pick-up IFS set up installed.

2500 'burb rear leafs bolt on the AWD vans giving a 2-3 inch lift and greater load capacity.
I don't know if they are same length as the RWD springs.
But like others have said, IFS is much harder than a solid axle 4x4 modification.

Look around for an AWD express and move your interior over to it.

 

[Len.Barron]

The thing is that I don't see how it would be much cheaper. The conversion vans I see here cost well over $15K for the AWD model. Usually closer to $20K. I got my 2002 chevy for $3800 (95K ODO, zero rust from NV) and I have made a campervan conversion. How much would a transfer case be? even if it's $1000, even if the axle is $1000, the driveshafts and new brake pads, rotos $1000, Even if I want to change the rear diff (a bit to noisy) for another $1000 and even if I add another $2000 for bits and pieces...

I get $6000 plus the cost of my van around $4000 it totals $10K. Still half the price of an AWD van in the same condition (zero rust, low mileage).

Are you able to do all this work yourself? There is considerable metal fab/welding required. The older frame design doesn't support IFS and would be very difficult to make the coil sprung solid front axles work, you would likely be looking at a leaf sprung solid front axle which is not known for it's comfort..