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2x4 to 4x4 conversion questions?

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Offline TreeFrogg169

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2x4 to 4x4 conversion questions?
« on: January 06, 2006, 08:16:03 AM »
I know this has most likely been covered before and i read a few posts about it but I have model year related questions.  I have a 96 2x4 DD and a 89 4x4 w/ a blown motor.  can I swap the front diff into the 2x4 or is the year gap to big?  Are all the holes, tabs and mounting brackets already in the 2x4 or am I going to have to fab some stuff?  They are both 5spds can I just change the tail shafts on the tranny to except the tcase or is it better to just swap the whole tranny?  One motor is a 8v and one is a 16v will the trannys swap out?  Thanks.

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Offline Dihnekis

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Re: 2x4 to 4x4 conversion questions?
« Reply #1 on: January 06, 2006, 01:56:52 PM »
Why don't you just put the 16v in the 89? It is a better body style anyway IMO.
1988 Suzuki Samurai

31" BFGs, SPOA, 5.14 Calmini Tcase gears, DOM cage, rock sliders, spidertrax wheels

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Offline jzap

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Re: 2x4 to 4x4 conversion questions?
« Reply #2 on: January 06, 2006, 06:35:40 PM »
I seem to remember someone on this board saying the splines on the shafts are different.  I'm sure somebody who knows for sure will chime in...
Jim Z.
96 Tracker
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Offline Dihnekis

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Re: 2x4 to 4x4 conversion questions?
« Reply #3 on: January 06, 2006, 06:45:11 PM »
There is a difference in the splines between those years (22 and 26 I think), but it doesn't really matter because he is going to be putting in a whole new front axle anyway.

One bracket will be missing, either get it from the dealer or cut it off the 4x4 you have.

I still just say swap the 16v into the 89, probably be easier.

Oh and you would need to swap transmissions too, the tcase you have on the 2wd is just a dummy tcase, and the transmissions are completely different. Unless you got lucky and have the rare 2wd tcase and tranny that are the actual ones out the 4x4, just without the gears. If that is the case you can bolt your tcase right up to the transmission, and use the 4wd driveshaft but I doubt it.

There isn't much fabrication but the bracket that is missing for the front dif will need to be welded on. You will need the complete front axle hub to hub, new front and rear driveshafts, and the 4x4 tcase and transmission. Sounds like a lot of work to me, just put the 16v engine in the 89.

Or go source out a good 8v motor and put that in, keep one trackick for play and one for getting to work.
1988 Suzuki Samurai

31" BFGs, SPOA, 5.14 Calmini Tcase gears, DOM cage, rock sliders, spidertrax wheels

1.6L, header, and 2" flowmaster exhaust coming soon

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Offline Shredder

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Re: 2x4 to 4x4 conversion questions?
« Reply #4 on: January 06, 2006, 07:16:02 PM »
I just bought my wife a nice clean '93 2wd and then picked up a rusty '92 4x4 for $75.00 as a parts donar. I will be doing this very swap sometime in the next few months. Dihnekis covered the process pretty well. I have heard that some 2wd frames do have the bracket for the front differential. Mine unfortunately does not. Still no big deal if you have a welder. Good luck.
'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50

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Offline Uncivilized

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Re: 2x4 to 4x4 conversion questions?
« Reply #5 on: January 06, 2006, 07:49:00 PM »
There is a pretty good writeup here on the conversion...
http://bbs.zuwharrie.com/content/topic,20946.0.html