1994 SAS 2wd to 4wd questions

[Chevymike]

Haven’t been on forums for a long time, remember this used to be a no bullshit crowd. Anyway I’m starting to gather parts to convert my 94 2wd into 4x4. Few questions and I apologize if the info is out there, I already attempted some searches, but I’m looking to see what I need to put a figure8 205 onto the current 2wd (early) 4l60e? (Pass drop) Next question is I have 60” and 64” springs to choose from I’d like to run on the front, wondering if that’s too much? I’m assuming I can do a crossover drag just like a squarebody? Lastly for now, is that dana60 bible on this site like pirate? Looking for Chevy spring center distances, I recall 32” but it’s been a long time lol...

 

[total newb]

31.5

Id use the 60"

Yes you can cross over

A round to fig8 adapter plate and the stock 4l60 adapters should work together but there may be sealing issues. Id tell you to read up on advance's site but it is an absolute pile of shit now so good luck with that.

 

[PAE]

From looking at the AA site some years ago sourcing a 6 bolt round np205 adapting the drivetrain could cost less with this adapter.

If the bolt pattern is the same and 4L60E output shaft the same assame 4L80E.

https://www.advanceadapters.com/prod...-bolt-pattern/

 

[Grendel]

Your frame is going to need a different leaf spring set up or link it.


ORD makes a set of 4 link brackets for a Chevy 60, I have a set here if you want them cheap.

https://www.offroaddesign.com/suspen..._list_dir=desc


For the T-case - Do you have a 4 or 6 bolt tail housing... I think it's 4?

https://www.offroaddesign.com/transf...-housings.html

You would need a 27 spline NP205, from behind a TH350, with the adapter.

You'll either need a short (4wd output in the trans) or a spacer to clear the longer output shaft. Should be 27 spline.

https://www.offroaddesign.com/700r4-...ith-bolts.html

That will let you use a stock TH350 to NP205 adapter. Cast iron, plenty strong.

They also have Ford adapters, but the Ford NP205 is the other side drop, round pattern (good for Ford axles) and a 31 spline input.

You will also need to figure out a VSS.

I've used this: https://www.dakotadigital.com/index....rod/prd916.htm

 

[rockota]

One of the magazine editors did a fantastic swap 15-18-ish years ago that covered all of the issues with using leafs. Iirc, ended up with 52” front leafs, shackles were rear, inside fram and tension. Might have been Ned Bacon, maybe. One of my favorite builds, but I no longer have the mags.

 

[total newb]

I redid someones cluster fuck off job of a sas years ago a got sold a set of 4" lift 52"s that turned out to be 56"s and they were perfect for ride quality and flexed good enough with engine hoist. Never got to wheel it though.

 

[Chevymike]

Thank you gentlemen, that spacer for the trans eases my worry of having to open the trans up, thankyou!

 

[Bigger_Hammer]

I have done this exact swap. 52" or 56" chevy rear springs will work. I made my own front-rear shackle brackets to work with 56" springs and clear long tube headers. To avoid messing with the transmission, I went with a ford divorced 205 converted to passenger drop to work with the Chevy 60 I had.

 

[Bigger_Hammer]

Here is the back of the NP205. The ford case worked the best for fitting up into the trans tunnel.

 

[Grendel]

I like that 205 mount. More pics on it, please?

 

[Bigger_Hammer]

Here are the shackle brackets...

What isn't shown is the finished work on these brackets and the fact I used sleeves through the box section of the chassis and bolted through the whole box section.

 

[Bigger_Hammer]

I like that 205 mount. More pics on it, please?

Thanks. I can't seem to find any more pictures on it. Basically it was two parallel pieces of square tube with a long bushing on each end that attached to the truck chassis via two small subframes. I built a small removable bracket to grab the two bolt holes on top of the case.