4x4 conversion

[twayne24365]

So since they use divorced transfer case could I use a 80s Dodge NP435 23 spline unit? Then use a diff clutch and flywheel and my mechanical linkage

[twayne24365]

I meant an 80s “2wd” NP435

[twayne24365]

ok guys, i finally got a chance to go look at the 63 and it was pretty much a basket case, i got the guy down to 1000 bucks but i just couldnt pay that for the only thing i cold use from the truck, "the front axle" every body pannel was completely rusted, floor pans were toast, rear axle was a dana 60 but the tubes were very rusty, motor was ok but had a bad miss, and a bad tap witch sounded like a broken valve spring to me, trans was leaking everywhere, the only good was the frame was in good shape.

so with the info from you guys and other threads in this forum i think i will find a newer dodge with a dana 44 with disk brakes for my front axle swap, i have seen a few divorced 205 transfer cases, and found a few np435s in various junk yards. so the new question is what year dana 44 front axles have the correct spring perch locations to bolt to my 69 d100?

[712edf]

So since they use divorced transfer case could I use a 80s Dodge NP435 23 spline unit? Then use a diff clutch and flywheel and my mechanical linkage

The 4x4 trucks that used the divorced transfer case (those are the 74 & older Dodges) used the same NP435 (23 spline input) as the 69 through 87 2wd trucks. In 88 the clutch changed back to hydraulic, but I don't think the transmission itself changed.

Bucky

[712edf]

Dana 44 fronts didn't get disc brakes until about 75.


Are you wanting to use 8 lug or 5 lug 4x4 axles for your 69?

Bucky

[twayne24365]

Thanks for the info, and bolt pattern doesn’t matter, I will have to get new rims anyway, I would however like to keep the dog dish hubcaps!

[twayne24365]

Ok guys, I about have my part list all figured out and most parts located. But I have another question, would a married transfer case make for a more simple/clean installation? Only one crossmember and eliminate the intermediate shaft? Or is it better to go with the divorced setup?

[dodgeboykim]

Ok guys, I about have my part list all figured out and most parts located. But I have another question, would a married transfer case make for a more simple/clean installation? Only one cross member and eliminate the intermediate shaft? Or is it better to go with the divorced setup?

Sure you can use a married T case. Front driveshaft from donor might fit up just fine (other than u joint issues if different). Rear shaft may be a custom depending on u joints ,Length etc.
Might be able to modify cross member from donor to work and you will probably have to cut original front (The one for the bell housing mounts if your truck has that style) cross member for clearance or remove entirely and replace rivets with appropriate bolts.

[Jim100]

I would look for a 1980 to 84 dana 44. Disc brakes and hand locking hubs. If possible get the ubolt top plates if you find a donor truck in a yard. The plates are harder to find than dana 60 plates.
jim

[twayne24365]

Thanks, and yea I found an 1980 Dana 44 disk axle with manual hubs, I did some measuring and it looks like it is going to bolt up fine

[Jim100]

searching on this forum will reveal ,if you don't know, the other details of the swap like brake master and shock mounts.

[twayne24365]

I have read about the master and shock mounts, I have a lot of stuff from this forum saved, one thing I haven’t seen much about is the pitman arm/drag link... will I be able to use the parts from my 69 or should I get those off the donor as well?

[Jim100]

I haven't installed my 1980 dana 44 yet. still rebuilding. I am not positive on pitman drag link issue. I have both a D and a W set. It may be a mix of the two.

[twayne24365]

Yea I figure if mine doesn’t work I’ll figure something out for it, when I get all my parts together I will document the complete swap so it’s all in one place for anyone else that wants to do the conversion

[twayne24365]

Yea I figure if mine doesn’t work I’ll figure something out for it, when I get all my parts together I will document the complete swap so it’s all in one place for anyone else that wants to do the conversion

[twayne24365]

Little update, truck still running good. I did get a running 383/np435 with all mounts and linkage parts from a 1969 d300, I’m going to rebuild the motor and freshen the trans while it’s out. I also got a divorced T case crossmember, all that’s left is a 205 and front axle. I decided on the divorced setup sine I now have a 2wd trans and a correct crossmember

[twayne24365]

I was having a hard time finding a divorced 205 close by, so I pulled the trigger on another NP435 with married np241 t case, front and rear driveshafts, transfer case shifter and linkage, and crossmember, it was a great deal so I had to get it

[Wildergarten]

They switched to mechanical clutch in order to mount the wiring connectors and fuse panel on the firewall where a clutch master would go.

Which is strange to me, as there appears to be a good spot for the connector on the flat just behind the air cleaner to the right (from the engine side) of the voltage regulator. I'm thinking of putting my '69 connector there and the fuse blocks just below that on the firewall. I might also put a folded up box over it just to keep the fumes and wind off it. I have no intention of running the high-current legs through that connector. Bulkhead studs only, over where the usual pre-'69 connectors will be were with a straight shot to and from the ammeter. I'm also thinking of keeping the 8-ga high current legs to the starter switch and fuse blocks in a separate harness from the harness on the distribution side.

Thoughts?

[moparbay]

That being said, is there a better way to do the 4x4 conversion than using the 63?

If you are NOT a purist, I would look for a mid 80s Dodge 4x4 donor truck. Disk Brake front axle. That is what I did on my '69 Slant 6 4x2. I used a 413 i had laying around used axles, transmission and transfer case and the Mounting crossmember out of the '85 w150. Like you, i had a BB bellhousing laying around. I did the whole shebang, engine and 4x4 swap at the same time.

[twayne24365]

I finally got a set of axles, Dana 44 disk front from an 80 w200, and the Dana 60 rear as well, axles seem in good shape so I’m just going to replace all the brakes then they will be ready, last step is finish up the motor!