These are some of the most common questions I get about our leaf sprung 4x4 van conversion kit. Feel free to email me for more details.
Q. The question I get asked most is "how much will the entire conversion cost me?"
A. There is no solid answer to this. Several of the main components vary in price. You may find a front axle for $250, $500, or $1500. Same with the transfer case, prices vary. If you do all the work yourself, you will save substantial amounts of $$. If you do some of the labor yourself, and sublet a few things that take more skill (transmission mods, fuel tank) you will still be in good shape. Some of my customers have taken their time to find good deals on parts, and some want the van converted asap. This is the beauty of my kit, you can do it at your pace. One thing that needs to be stressed is that the 4wd conversion is an investment!! It will hold it's value!!
A turn key conversion from us here in NC starts at around 20k depending on a few specifics
Q. What is the best/worst year to convert? A. There isn't one! Your donor van all depends on your needs. Cargo vs passenger, regular body vs extended, gas vs diesel are the biggest choices.
Q. What vehicles will the kit fit?
A. My kit fits the 92 to current Ford E series chassis. E150 - E450.
Q. Will I get instructions?
A. Yes, a detailed step by step instruction sheet is included, we also have a video on the website and YouTube to help.
Q. Does the conversion require any special tools?
A. Nothing specific. A 90 degree drill or plasma cutter will make the shackle sleeve install much easier. Welding is required.
Q. What axles can I use for the conversion?
A. My kit is designed to use 99-04 Ford F250/350 & Excursion front axles. These came as Dana 50's as well as Dana 60's. These axles have a 38" spring pad width, ball joints & unit bearings. You can retain ABS with these axles (if you choose). The super duty axle is a bolt in unit for this kit, no modification to the axle is needed. When searching for an axle, make sure it's complete with u-bolt plates & a sway bar. If you plan a 6" lift or larger, the upper u-bolt plates will come with the UJOR trac bar kit. Any 08/up van will need an axle from us with the RSC upgrade to retain the ABS/RSC system.
Q. What is done about the bolt pattern difference?
A. The donor axle will have the 8 on 170mm bolt pattern, and the vans are 8 on 6.5". There are a few options to make the change. Option 1: Install rear wheel spacers that change the bolt pattern as well as increase the trac width to match the front. Option 2: Swap the rear axle assembly to a Sterling 10.5" (disc brake). We can also do a hub conversion for the front or equip an axle with the RSC upgarde to 8 on 6.5.
Q. What's the lowest lift with the conversion?
A. The minimum lift is 4". This lift height will fit up to a 33" tire. The lift sizes go in 2" increments. 6" lift for 35's, 8" lift for 37's. Lower than a 4" lift isn't possible due to differential clearance with the engine cross member.
Q. Does my engine crossmember need trimming?
A. Yes, all conversions require engine x-member trimming.
Q. Does my exhaust need to be modified?
A. On gas models, yes. The drivers side exhaust will need to be re routed in order to make room for the front driveshaft & transfer case. Diesel models don't require exhaust mods.
Q. What steering parts do I need?
A. UJOR kits require crossover steering. All wearable parts are available at any local parts store, and the factory F250/F350 tie rod is utilized.
Q. Does my fuel tank need to be modified?
A. Yes, the fuel tank will have to be shortened to make room for the transfer case. I have fuel tank shortening kits available as well as an Aluminum replacement tank. If you have a 5.4 with the plastic fuel tank it can be retained.
Q. What do I do about a transfer case?
A. I recommend to have your transmission removed to have the output shaft & tailhousing replaced with 4x4 truck parts on all E4OD, 4R100 and 4R75 transmissions. We offer a kit for the 5R110 transmission, it doesn't have to be removed. We use the NV271 transfer case and we sell rebuilt units if you don't want to source one locally.
Q. What do I do for shocks?
A. I have several shock & mounting options available. Standard is a single front shock, dual shock towers are available too. We currently use Fox shocks.
Q. Will extended brake lines be needed?
A. Yes, I offer custom steel braided DOT brake lines for every lift height.
Q. What do I do about driveshafts?
A. For the front you can use a 99-04 truck shaft as a donor but it will have to be lenghtened. For the rear you'll need a new shaft made from scratch. Any local or mail order driveshaft shop can handle this. I reccomend to measure the flanges on the t-case and axle before doing this. There are many variables so get it right the 1st time! 4" lifts can use a single joint/single joint shaft, 6" & 8" kits require a CV on the rear shaft at the t-case.
Q. How much time does the conversion take?
A. It all depends on skill level and the tools available. I recommend to install the front spring hangers while the van is still 2wd. All you need to do is remove the front bumper, remove the sway bar, and start drilling. Then the van can continue to be driven in stock 2wd form. With a lift and proper tools, the axle can be installed in a full day. The other major components will depend on the suppliers time frame. I generally estimate 40-45 hours for a complete install.