4 Wheel Drive Van | 4 Wheel Drive Vans | 4x4 Van | Parts | Kits

More Inspiration

Smaller than a motor home yet larger than a Jeep. Like the dual purpose motorcyle these vans will not excel at everything but they bridge the gap between full size camper and nimble Jeep very nicely.

Inspiration for this project.

Every project gets its inspiration from somewhere. Seeing these two 4×4 vans in Moab Utah set the gears in motion.

Need to buy more tools

Posted by Mike on August 1st, 2010

I thought I had a decent set of tools but then I went to tear down this 10.5 Sterling rear axle and realized I needed more. I’ve got a couple 24mm short sockets and even a few 24m wrenches but without a deep 24mm socket I could not remove these bolts. A quick trip to harborfreight.com and about $40 solved the problem. Shipping took about a week which is no big deal because I’ve been so busy with my day job that I have not been able to spend much time on the van this week. Here it is Sunday and I’ve got a few free hours so I thought I’d post a picture or two.

24mm deep socket

Shock mount removal – I went through 4 grinder disks. Wish I had a plasma cutter!!!

Grinding off the shock mounts

One mount off, one to go...

All cleaned up and ready for paint.

Another Tool to Buy – 4 lug spindle nut socket to allow me to remove the rear axle hubs.
Reference Video

More Inspiration

Posted by Mike on July 28th, 2010

Smaller than a motor home yet larger than a Jeep. Like the dual purpose motorcyle these vans will not excel at everything but they bridge the gap between full size camper and nimble Jeep very nicely.

Inspiration for this project.

Posted by Mike on July 28th, 2010

Every project gets its inspiration from somewhere. Seeing these two 4×4 vans in Moab Utah set the gears in motion.

F350 Rear End – Half an hour with a grinder but still needs a little more cleaning before prime and paint.

Posted by Mike on July 21st, 2010

f350 rear hubs shaft and pumpkin

This axle has significantly less rust than my front axle did. The only parts that I will be replacing are the rotors, brake pads and e-brakes.

f350 brake caliper rust removal

The 4″ grinder removed most of the rust off the larger areas, I’ll have to use some smaller sanding wheels and metal brushes to get into the nooks and crannies before I prime and paint with POR15.

ford 12 bolt - Sterling 10.5 rear end

Sterling 10.5 differential

Sterling 10.5 axle for a 4×4 Ford Van Conversion, Q & A with Chris Steuber of Ujoint Offroad.

QUESTIONS:

Can I reuse the shock mounts that came with it?
Are the spring mounts on the axle now in the right place or should I grind them off?
There is some electrical crap on top of the front of the differential. Do I need to keep it?
Is there a real need for the brake dust shields or can I run the van without them? Mine are pretty beat up.
With your kit will I be re-using any of the brake lines currently on the axle or can I pull them all off now?

ANSWERS:

The shock mounts aren’t in the correct location, so you’ll need to weld some new ones on. Same with the perches, they’re not the correct spring pad width. The electrical connection on top of the axle is critical, that’s the VSS sensor. Your van should have one too, and it needs to be plugged in. Check the part #’s between them, they should be the same. No need for the brake shields, I hate those things!! You will be re using the brake hard lines, so keep them or run some new ones if you want them to be pretty. (who doesn’t want that!)

Another trip to the salvage yard.

Posted by Mike on July 21st, 2010

I saw this center console the last time I was at the salvage yard but for some reason did not pick it up at that time. Price for greater drink capacity? $10.00

Room for four drinks is significantly better than room for one.

They are wet and soapy because I just cleaned them off with the power washer.

Sterling 10.5 Ford F350 Rear Axle Arrives

Posted by Mike on July 20th, 2010

Sterling 10.5 F350 Rear Axle

sterling 10.5 rear axle

The BFH did not work as well as the puller on these stubborn rotors

The sterling 10.5 axle shafts seem to be in great condition.

Rear Axle Assembly

Donor Vehicle
Model	FORD F350 SUPER DUTY
Year	2004
Mileage	113000 Miles
Stock Number	090644
Store Number	1

Notes: 4X43L73,BLU,11-03,6.0,COL-AT,OWC

This part will fit these makes and models with these options

EXCURSION 02-05 (10.50 RG), 3.73 ratio
FORD F250SD PICKUP 02-04 3.73 ratio, tag S141H
FORD F250SD PICKUP 02-04 3.73 ratio, tag V414B, C and F
FORD F250SD PICKUP 02-04 3.73 ratio, tag V420B, C and F
FORD F250SD PICKUP 02-04 3.73 ratio, tag V423B, C and F
FORD F250SD PICKUP 02-04 3.73 ratio, tag V425B, C and F
FORD F350SD PICKUP 02-04 10.50″ ring gear, SRW, 3.73 ratio, tag V420 series
FORD F350SD PICKUP 02-04 10.50″ ring gear, SRW, 3.73 ratio, tag V423 series
FORD F350SD PICKUP 02-04 10.50″ ring gear, SRW, 3.73 ratio, tag V425 series

Turning a 4R70W 2WD Transfer Case to 4WD

Posted by Mike on July 19th, 2010

Supposedly these are the parts I need to mate my 4R70W transmission to a BW1356 Transfer Case. Installing the 4×4 tail shaft requires a total transmission tear down.

4WD Tail Housing F2TP and 4x4 tail shaft.

4R70W 4x4 tail housing

Another Bumper Post: Shackle Mount Mounting

Posted by Mike on July 19th, 2010

I decided that rather than just weld these to the face of the bumper I would counter sink them and plug weld the back as well as weld the front for additional strength.

A little work with the grinder in the 2" x 6" 1/4" steel and there's now room for my shackle mounts.

Shackle Mount in place ready for welding.

4x4 van rear bumper

4X4 Van Bumper Accessories: Shackle Mounts

Posted by Mike on July 16th, 2010

Photos can be decieving. The hole is 1" The base is nearly 6" long.

Rather than try to fab these shackle mounts up myself with my limited collection of tools, I purchased them on Ebay for about $10.00 each (which appears to be less than half of what they cost everywhere else). They may look small in the picture but they are pretty massive and made of 1″ thick steel.

Ujoint Offroad Install: A bigger drill

Posted by Mike on July 16th, 2010

The cordless drill was lacking power when trying to turn a 3/4 " Bit.

ujoint offroad. Mounted, driled, ready for paint

Mounted, Drilled and ready for Paint

Ujoint Offroad Install: Drilling the Pilot Holes

Posted by Mike on July 16th, 2010

I really need a day off without interruptions so I can get some work done on the van. It’s difficult to make much progress working an hour or so after dinner in the evenings.

Drilling pilot holes for the front Ujoint Offroad brackets.

Ujoint Offroad Install – Part 1

Posted by Mike on July 14th, 2010

Due to crappy ungodly hot, humid rainy weather I did not do any drilling or welding today but I did pull the stock front sway bar and put the Ujoint Offroad brackets in place.

removing the stock e250 sway bar

Ujoint Offroad bracket in place

Interesting photo, you can see all the way from the front bumper bracket to the rear windows.

Ujoint Offroad Brackets in Place - Waiting for Drilling.

The 64 Dollar Question

Posted by Mike on July 13th, 2010

What do the numbers on the transmission mean? This is a 1997 4R70W RWD transmission.

64 dollar question - 1997 Ford 4R70W Transmission.

I don’t know, I don’t know, I don’t know if Jimmy Buffett is a reader of my blog…

Posted by Mike on July 13th, 2010

But I do know he has a thing for 4×4 Vans. Here are photos of two Sportsmobile
4×4 vans he is said to own. Supposedly he has one for the East Coast and one for the West.

One of Jimmy Buffett's 4x4 vans - Tidal waves out on the sea.

Another one of Jimmy Buffett's 4x4 vans - Ground she's moving under me.

But I don’t want to land in New York City

Don’t want to land in Mexico, no, no, no

Don’t want to land in no Three Mile Island

Don’t want to see my skin aglow, no, no, no

Don’t want to land in Comanche Sky Park

Or in Nashville, Tennessee, no, no, no

Don’t want to land in no San Juan Airport

Or the Yukon Territory, no, no, no

Don’t want land in no San Diego

Don’t want to land in no Buzzard’s Bay, no, no, no

Don’t want to land on no Ayatollah

I got nothing more to say

Santa pays a visit in July

Posted by Mike on July 13th, 2010

1 Ton Warn Premium Hubs

Warn Premium Locking Hubs $207.00 on Amazon.com

F350 MOOG Ball Joints

Before purchasing these I never realized Ball Joints were so expensive.
You are looking at about $200 of Moog Ball Joints.

4x4 van kit - Ujoint Offroad

Here are the first parts that I’ll actually be bolting to the Van and the first step in making the conversion from rear wheel drive to 4 wheel drive. I’ve watched the Ujoint Offroad Video about a dozen times and read the instructions twice and feel that I’ ready to start drilling into the van frame. I’m guessing the install of these parts should take me less than an hour and as long as no family emergencies pop up between now and this evening I plan of doing it tonight.

UJOINT OFFROAD 4x4 Van Conversion Kit

The cost of this 4×4 van conversion kit (as of July 13, 2010) is $595. Chris of Ujoint Offroad was extremely helpful in answering all of my 4×4 van conversion questions. If you would like to order the same kit ask for Part #: CK001
Unlike the Moog Ball Joint and Warn Hub sellers, Shipping from Ujoint Offroad was LIGHTNING FAST.

Ujoint Offroad also sells most of the other parts you will need to complete your conversion including: axles, springs, brake line kits, wheel spacers, steering kits, front frame supports, u bolt kits, spring perches & shock mounts, front shock mounts, sway bar mounts, fuel tank shortening kits, fender flares and more. I’d be surprised if you have a 4×4 van conversion question that Chris from Ujoint Offroad cannot answer.

You can reach Chris at 818.606.5206 or chris@ujointoffroad.com

Slow Bumber Progress

Posted by Mike on July 12th, 2010

Slow drilling in 1/4 steel

It's time to buy a bigger - better welder.

Van Bumber one step closer to done.

I’ll be wrapping the bumper around the rear of the van all the way to the end of the rear fender. On the right side I’ll probably drill a 3″ hole for the exhaust to exit and mount the bottom of a heavy duty ladder. On the left I’ll add a swinging arm to hold a spare tire and a drink holder In the middle I’ll add a mount for a Hi-Lift Jack.

Getting Started on the Rear Van Bumper

Posted by Mike on July 10th, 2010

E250 with Bumper Removed. Nice view of the Dana 60 diff to be replaced with a Sterling 10.5

Measuring total length of the rear of the van

Chop saw on 1/4" thick 2" x 4" for new bumper

I promise it will look a lot better before I'm done!!!!!

POR15 – Second Shipment

Posted by Mike on July 9th, 2010

I used POR15 rust preventative paint on my front Diff and liked it so much that I will be using it to coat the entire frame and bumpers. I’ve been chatting them up so much maybe they will offer me a discount on my next order because this stuff is not cheap. You are looking at a $100 of product.

POR15 Products

Break these shackles – not anytime soon.

Posted by Mike on July 9th, 2010

3/4 " 4 Ton Shackles

Here is my daughter Morgan modeling our most recent find. They are rated for 4 3/4 tons each and I picked up 4 of them for my custom bumpers from the local metal supply yard for $32.00 ($8.oo each). Let me know if you are in need of some of these. They have tons of them at this price and I’m always looking for an excuse to visit the metal shop.

2 1/2 inch square tube for a 2 inch mount.

Building my own hitch mount to stick in the custom bumper I’m building. 2 1/2 ” square tube fits a 2″ hitch. (Some internal grinding required). This will never be used to carry anything heavier than a motorcycle or a cooler full of beer behind the van. I’m not sure if factory made hitches are made out of a special type of steel but this will certainly work for what I am going to throw at it.

Scored some Trim and Windows at the salvage yard.

Posted by Mike on July 9th, 2010

Ford E Series Van opening side windows and trim

My cargo van was great for hauling material but not originally set up for camping. These opening side windows that I found at the salvage yard should help with ventilation. I also found the large plastic footwell and rear door plastic trim that you see above it. My originals were pretty beat up from 10 years of construction work. Total price $50.00

Van High Top Installation

Posted by Mike on July 9th, 2010

High Top Van Installation.

This post is more of a “Post-It Note” for myself than an article.

Next week I may tackle pulling a high top from a doner vehicle to install on my own E250 Ford Van.

Here’s what I will be getting myself into if I decide to take on this project:

One Man’s Trash Is Another Man’s Treasure

Posted by Mike on July 9th, 2010

Like it or hate it the US Government Cash for Clunkers subsidy has provided us with a large
quantity of used parts for our 4×4 van builds.

This van has seen better days

A trip to the dump. Cheaper than Ebay and NO shipping charges!

These donors are nicer than my project car.

Today’s Goal? Locate some plastic trim and side windows that open. I may be back for the high top later this week.

Just play with the M35A2 Military truck while Dad pulls some van windows...

Nothing like some father-daughter bonding at the salvage yard.

What is this? Heating? Cooling? Both?

Question for my readers. Is this unit for heating? Cooling or both? Is it more or less plug and play
or are there other parts required to make if work?

That’s the Breaks, F350 Brakes that is.

Posted by Mike on July 7th, 2010

ford f350 brake calipers. Old vs. New

I could have spent two hours cleaning the rust off the old ones, another hour installing a rebuild kit and then a little more time putting a protective coating on them. Instead of that I went with the $50 each option and just purchased re-manufactured Ford F350 Brake Calipers. Now all I have to do is remember to ship back the old cores so that I do not get charged a core fee.

Ford F350 remanufactured Brakes

Dana 60 Knuckle Sandwich & Other Photos

Posted by Mike on July 7th, 2010

2002 Ford f350 dana 60 knuckles

Ford F350 front Hubs New vs. Old

Notice the wheel studs on the new hub are a good deal longer than the original.

Ford F350 2002 Front Wheel 4x4 Hubs Top View

front view 2002 F350 front wheel hubs

Here's why I hate the Ford dealership. 8 Bolts 41 Dollars.

I purchased my entire Dana 60 front differential for $300. Hubs run about $80 dollars each, rebuilt brake calipers are about $40 each. Brand new rotors are just over $50 each. Somehow when you go to a Ford dealership prices travel through a time space continuum and end up being five times more expensive than they should be. Hopefully these will be the last items that I have to purchase from a Ford Stealership. If the parts were 5 times better or the service were clearly superior I might understand it but such is not the case. Usually the discount on line parts place has better knowledge and customer service.

Dana 60 Front Axle U Joint Install

Posted by Mike on July 7th, 2010

They certainly went in a lot easier than they came out. Even with a ton of Liquid Wrench the old U Joints were rusted in place and a real pain to remove. The new ones took a bit of pressure with a C-clamp and a couple of whacks with a BFH.