4WD Conversion - E350 5.4L

[skumancer]

Hey everyone, been lurking this forums for more than a year. I bought a 2008 E350 Super Duty Extended Van with a 5.4L engine last year in January, to build it out as a travel and adventure van.

Been slowly building it, hit a snag about a month ago when changing the transmission fluid found a piece of a retainer ring from 3rd/4th year that required a transmission rebuild. While out, I decided to convert it to 4x4, as it made sense to do it now that the transmission was out.

Sourcing the pieces for this in Latin America (Panama specifically) has not been easy, but I pieced together a BW1356 T-case with 31-spline input out of a 1996 F-150 (year is approximate) and got a 31-spline output shaft for the transmission as well as a transmission to T-case adapter.



Tank was cut and re-welded to fit the transfer case. Exhaust was cut and will need to be properly routed.


Posting some pictures I have available, more to come as I keep piecing this together. Still need to figure out drive-shafts, front axle, transfer case shifter and so much more…

 

[RVflyfish]

It’s awesome you’re going for it from Panama. 4WD conversions are daunting even here in the US.

Not sure if you have access to late model F250 and 350 Super Duty trucks there, but the 2013+ front axles have big brakes. Pretty helpful with a big heavy van.

 

[motovan_mn]

Definitely following along in this thread, please keep us updated!

 

[skumancer]

It’s awesome you’re going for it from Panama. 4WD conversions are daunting even here in the US.

Not sure if you have access to late model F250 and 350 Super Duty trucks there, but the 2013+ front axles have big brakes. Pretty helpful with a big heavy van.

That’s what I’m trying to source. We have F-trucks, but they’re not as easy to find in junkyards or well-kept pieces. Crossing my fingers for a good find soon…

 

[skumancer]

Transfer case is in. Had to remove all the exhaust of course, and now working to get the rear driveshaft shortened temporarily while I order a permanent one after the truck is lifted…


Got the brackets for the crossmember cut and welded, used 1/4 inch steel plate I had around. Coat of paint and this should be ready to move.

 

[skumancer]

Ok, more progress, we got the rear driveshaft cut, so I can get it out of the transmission shop. I also replaced the U-joints with new ones, given the old ones looked like they had been there for a million years.



I'm going to get custom ones made one we have the final suspension installed and the front diff in place. For now, we just need it to roll down the road.

As soon as it's rolling, I'm taking it to the exhaust shop to get the new exhaust built, as it's running fully open pipe right now.

 

[skumancer]

Got the van back from transmission shop and exhaust guy did his job (he also did the tank shortening and driveshaft shortening).




Now my problem lies with the transfer shifter bracket. I can only find one for an E4OD, but I need one for an AODE-W...Any help finding one would be greatly appreciated!!



The middle one here is the one I need:

 

[CaptainBuilt]

What did you have to change on the exhaust?

 

[skumancer]

What did you have to change on the exhaust?

The routing has to be moved to clear the transfer case!

 

[FurthurOnTheFly]

A little off topic but tell me how you feel about the 5.4l V8 and traveling with it? Prior to finding these parts for this project, did you feel maintenance was easy enough south of the border?

We're looking for our next rig and the 5.4l are plentiful and not at the astronomical prices people are asking for a Triton V10 or the 7.3 so we're starting to consider them, but everyone is warning us they are underpowered, etc etc.