Need 1 ton 2x4 to 4x4 conversion advice

[monolith]

Just got a 65 GMC 1 ton panel and I need some advice on how to convert it to 4x4 eventually. My goals are: heavy duty and bulletproof- ultra reliable for back country travel- I won't be rock crawling or mud bogging- I just need a stable overland rig. I'd ultimately like to convert it to diesel- likely a chevy 6.5 turbo for ease of the swap.

Any advice as to axles, steering, transfer cases, adapters, cooling for offroad- I'll probably keep the SM420 that's in it- it shifts like brand new.

Any articles, websites or books I should be reading to study up?

Thanks in advance for your time and advice.

[88bagedntaged]

Originally Posted by monolith

Just got a 65 GMC 1 ton panel and I need some advice on how to convert it to 4x4 eventually. My goals are: heavy duty and bulletproof- ultra reliable for back country travel- I won't be rock crawling or mud bogging- I just need a stable overland rig. I'd ultimately like to convert it to diesel- likely a chevy 6.5 turbo for ease of the swap.

Any advice as to axles, steering, transfer cases, adapters, cooling for offroad- I'll probably keep the SM420 that's in it- it shifts like brand new.

Any articles, websites or books I should be reading to study up?

Thanks in advance for your time and advice.

Well the years are off but I have converted a 88 crew cab R20 to SWR to a R30 DRW. The swap was easy, for 1 reason I found a 1975 chevy 3/4 to 4x4 and used all that I could off of it. I have pics of the mounting points for the front Axle and such that I can share with you if you want. Check out the Diesel Wrenchers builds, he has converted one closer to your year. Let me know on the pics and I will help where ever I can.

[Monty]

i'm doin' a '72 Suburban 3/4 ton 2wd to 4wd and it is easier than i thought it would be, but i have some help in the way of the DIY4X FGB52 kit for the front and the shackle flip kit in the rear that gives me most of the leaf spring mounts. i will have to fab the front perches for the rear springs though.

i'm using rear 1/2 ton 52" springs in the front and late model 3/4 ton 64" springs in the rear. the axles of choice for off road seem to be the corporate 14 bolt full floating rear and Dana 60 front. i scored both of these locally (although they wern't cheap)

i'm also mulling the idea of the 6.5 diesel, but i do have a 427 truck engine with low miles that may go into it first. dunno.

i was afraid of this project before i started it, but after getting started i'm not too worried. there will be a lot of parts to hunt down, but that is half the fun.

[monolith]

Thanks for the responses and encouragement guys!

Thanks for the info Monty.

I'll go look for Dieselwrenchers build to get some basic ideas- 88, I may hit you up for more info when I actually get closer to the swap, I'm sure I'll need the help. I'm in the basic research phase right now, so I'll look and see how you guys did yours. I'm not in a huge hurry to blow this thing apart til I have a better idea of how to proceed.

[Average Joe]

Updates on either build?

[OrrieG]

Not the same, but theory and some of the issues I encounted and solutions might be helpful. Link to the build thread is below.

[Your41Plague12]

For a transfer case, the way to go in my opinion is the NP205. It's pretty much bulletproof. For the front axle, go with a Dana 60 if you can find one. People run 44's on these all day with good results. Match that with a full-floating 14 bolt rear axle, and you'll have a good axle setup. Have you considered how you're going to mate your SM420 to the transfer case? The easiest way would be to run a divorced setup, but if you use a transfer case from a Ford, you'll need a Ford front axle to match because the pinion is on the other side. For springs, I also second the 52's up front. With some fabrication you can make them work, and stock 52's up front will yield about 3.5-4 inches of lift. So depending on how much lift you want, order "X amount of lift 52's" and add 4 to it, for the total lift. These springs were stock on most 73-87 half tons in the rear. For your rear suspension, I would either get some springs made or get some Tuff Country EZ Ride springs for however much lift you want. The Dana 60 swap won't be just a bolt in job either, there is some fabrication involved in the steering and also where the spring perches should be placed. I'm interested in seeing how this goes for you, I'll be watching!

['63GENIII]

The dodge 205 is also a pass. side drop that came in a divorced version too. I picked up a NP201 out of an International which appears to have the same helical cut and huge gears as the 205, just not nearly as compact an light (compared) as a 205. Got it for 50$, it was twin sticked and has the drum parking brake which I thought was kinda kool.