1992 d250 convert to 4wd

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1992 d250 convert to 4wd

Postby coalroller1 » Tue Oct 22, 2013 2:36 pm

ok finally underway for this project

starting with a 1992 d250 5spd low miles and in great shape (white lightning)

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picked up this beaut for $500 with a good motor yet
1990 w250 12v auto tranny with np205 with a locking rear d70
and dads 24v hauling it
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first took the rear axle and freshened it up with brakes, seals, bearings (sorry im still in school and no time for paint and prime)
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next I redid the u-joints and seals and bearings on the donar truck (big red) with the axle still on the truck
and pulled the motor, tranny, and transfer all in one shot

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pulling the front axle and springs off
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that's all for this past weekend stay tuned!
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Wed Oct 23, 2013 5:58 pm

last night i got everything stripped off the donar
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the 23 spline sleeve ill have to replace with an adapter that uses both
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ok now I need some help should i switch crossmembers and make a template using the old frame?
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or should i just cut the fat off my 2wd crossmember and line the shock mounts up the best i can? im also lost as to where i can get new "t-shaped" rear spring mounts and how i lay out the holes for them?
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any advice or help please?
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Re: 1992 d250 convert to 4wd

Postby CumminsPower59 » Thu Oct 24, 2013 11:38 am

1. Front leaf spring shackle hanger bushings can still be had from the stealership, they are under the frame section in thier parts diagrams on the computer.

2. I wouldn't have wasted much time going over the 92 D70 as if you are going to use the D61F that came under that 90, I'm betting that it has 3.07 gears in it, so you'll want to use the rear D71 that came with it also, as your 92 probably has 3.55's.

3. Use the 4wd frame's engine crossmember. Burn the rivets out of both, and bolt in the 4wd crossmember in to your 92's frame.

4. Cut down the 90's front frame section and use the sides as a template for getting the holes in the right spots.

There are several build threads on here, there is one done by "1990" that is really good. Do some searching and you will probably find that there is a good amount of things to consider and do on a conversion like this :thumright:
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Fri Oct 25, 2013 1:31 pm

ur correct! but i forgot to mention i actually did use the d70 off the 1990 donar and switched the rear springs and installed the blocks on my d250 so that the rear end has the 3.07's in it already, i did order new bushings and and managed to get the shackle mounts out ok (they are a pita to remove the old bushing)

and i have torched one full side of frame out to use as a template, i realize how critical the alignment and everything is for this front axle just taking my time
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Mon Nov 04, 2013 11:15 pm

so here's my second full weekend of work accomplished i got tired of washing my hands to take pictures so i got mostly after shots


glad i changed the crossmember, drilled 6 holes and done, way nicer job
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ordered these new bushings from rockautoparts.com 1" od 5/8" id were a bugger to press in but i got 'em done, also im glad the mount holes were already drilled in the frame (please not this is not my exhaust work)
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used a gearbox i got at the scrap yard, had to drill the frame holes out to 5/8" but a perfect fit, this one also has a beefier collar for the input not the chinsy shimmed ones that always leak and wobble
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i didn't get a long enough steering shaft to reach so i just pounded some box tubing over it and applied mig weld to extend it :roll:
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front spring hangers bolted in using the 4wd radiator support (rubbers on it were wore out of course)
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my shiny new crossmember bolts
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hard to believe there's this much crap involved on a 2wd
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all done and tightened up now just waiting on napa to get me the brake lines i actually need :evil:
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Last edited by coalroller1 on Mon Nov 04, 2013 11:26 pm, edited 1 time in total.
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Mon Nov 04, 2013 11:20 pm

the last picture i have of her stock ride height and now that it gets dark here in pa before i get off work idk when ill get a finished shot
Image
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Mon Nov 04, 2013 11:22 pm

my 1st gen boneyard also since the donar truck had a hydraulic dump bed heres a sneak peak of our gravel trailer were conjuring up
Image
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Mon Nov 04, 2013 11:36 pm

so hopefully ill have my adapter and will be able to put the transfer case on this coming weekend, anybody got a link for how to run the exhaust the proper way?

also which driveshafts will work? i have both drive shafts off my donar but it was an auto and the getrags are quite a bit shorter has any body come up with a way to use a carrier shaft on a 4wd?

and the closest driveshaft shop is an hour away from me :(
2006 volkswagen jetta gli 2.0tfsi, 6 spd, fuel pump 3" turbo back exhaust stage 2 goodies
1992 d250 converted to 4x4, 5spd getrag, 3.07 running gears
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Re: 1992 d250 convert to 4wd

Postby BHD » Sun Nov 10, 2013 8:32 am

coalroller1 wrote:also which driveshafts will work? i have both drive shafts off my donar but it was an auto and the getrags are quite a bit shorter has any body come up with a way to use a carrier shaft on a 4wd?

and the closest driveshaft shop is an hour away from me :(


If you changed the mainshaft in the G360 and married the transfercase to it, the donor's driveshafts should work. I swapped my auto for a standard and reused both shafts with no issues.
1990 W250, 185K, 727 to G360 conversion, 3.07's to 4.10's, straight piped, BHAF, 2.5" Skyjacker springs, Autometer gauges, 285 Cooper STT's,
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Re: 1992 d250 convert to 4wd

Postby CumminsPower59 » Sun Nov 10, 2013 9:28 am

BHD wrote: If you changed the mainshaft in the G360 and married the transfercase to it, the donor's driveshafts should work. I swapped my auto for a standard and reused both shafts with no issues.


Yup. The Getrag and 727 trucks share the same length of driveshafts...so I've heard.
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Mon Nov 11, 2013 5:34 pm

CumminsPower59 wrote:
BHD wrote: If you changed the mainshaft in the G360 and married the transfercase to it, the donor's driveshafts should work. I swapped my auto for a standard and reused both shafts with no issues.


Yup. The Getrag and 727 trucks share the same length of driveshafts...so I've heard.



awesome! thanks guys
2006 volkswagen jetta gli 2.0tfsi, 6 spd, fuel pump 3" turbo back exhaust stage 2 goodies
1992 d250 converted to 4x4, 5spd getrag, 3.07 running gears
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Mon Nov 11, 2013 5:44 pm

never even realized i didnt have this lower cowl till i went to put my new grill on, so just used the one off the 90 :roll:

Image


anyways here she is all i need to do is mount the transfer case now, but sitting pretty level

Image

Image
2006 volkswagen jetta gli 2.0tfsi, 6 spd, fuel pump 3" turbo back exhaust stage 2 goodies
1992 d250 converted to 4x4, 5spd getrag, 3.07 running gears
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Re: 1992 d250 convert to 4wd

Postby CumminsPower59 » Mon Nov 11, 2013 9:11 pm

Looks pretty good!
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
04 VW Jetta Wagon TDI 5speed
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Re: 1992 d250 convert to 4wd

Postby bgilbert » Wed Nov 13, 2013 6:00 am

So did you use the 'template' method to locate and drill the holes? I'm wanting to convert my crew to 4x4. It's been a long term project that I haven't gotten to yet. I have all the 4x4 frame parts and the front frame section to use as a template.
Bill Gilbert
85 D350 crew with 90 6BT intercooled Getrag 3.07's
93 D350 single cab Getrag 3.54's.
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Re: 1992 d250 convert to 4wd

Postby coalroller1 » Thu Nov 14, 2013 2:22 pm

well kinda, I cut the section of frame off but didn't use it as a template, instead I clamped a sturdy piece of cardboard onto it, and traced all the holes out with a sharpie, then sharpened a 1/2" piece of copper tubing and used it has a hole punch to trace them out on the frame nicely
2006 volkswagen jetta gli 2.0tfsi, 6 spd, fuel pump 3" turbo back exhaust stage 2 goodies
1992 d250 converted to 4x4, 5spd getrag, 3.07 running gears
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