Well, I've been thinking.. (scary, I know) I've looked into doing an SAS on my 03 Chevy 2500HD, and the project wouldn't be to incredibly hard, but I"m having trouble locating information on converting it to a 4x4... most articles I've found people have said that the conversion from 2wd IFS to 4wd IFS would be a horrible project due to the complicated IFS. But I figure if I"m swapping out the front suspension then maybe it won't be so hard? What do ya guys think?

I know how this sounds, and please forgive me Jeepus, but maybe you should have kept the Chero.

Had to pay bills :( Believe me I wished I still had it.. I"m just throwing around ideas right now, I may be getting a 93 chevy 4x4 early next year for pretty much nothing cause my buddy owes me. If that happens, then I'll do an SAS to that

Better idea.
Have never heard anything good about giving the ol 4x2 as my sis calls it "a sex change"

lol.. that is unfortunate. an 03 2500 with an SAS would be sooo awesome..

It'd be cheaper to just switch the body.
I still think Alan should do this with his XJ's.

hahaha that is awesome!!






(hows the tool box coming?)

Avis wrote:
(hows the tool box coming?)

Right now it's an expensive table

Whatcha doin to his toolbox?

A SAS would be fairly straight forward. If you take a look at the link below it shows it is possible.

http://www.cardomain.com/ride/3123740/r1

If it were me I'd take the trans and t-case from a 4wd chevy and the front axle and suspension from...oh, I dunno...a 4wd Dodge or something and throw it underneath. That way all you have to do is line up all the parts, build a few custom brackets, order a custom driveline and call it good. If my thinking has no flaws, it would be the most cost effective means to do the swap. If you take it to a shop around here odds are they have already done at least a few SASs and are capable of doing everything custom. If you've got the money just pick up a D60, put it in the bed, drive over to a shop and say "I'll be back in a week!" ;)


BTW, apparently both pirate and pavement sucks have write ups for exactly what you're looking for.

And check this out
http://www.fullsizechevy.com/showthread.php?383899-2-SASes-1-garage...-Summer-2009

lol I realize the axle swap is easy... the whole converting it to 4wd is the problem

How? Aside from a few missing parts your truck is the same as a same year and model 4wd one right? Just steal a trans and t-case from a 4wd or mix and match. Am I right?

AZCA jeeper wrote:How? Aside from a few missing parts your truck is the same as a same year and model 4wd one right? Just steal a trans and t-case from a 4wd or mix and match. Am I right?

theoretically I suppose that would work. Bout 5 grand... if I find good deals on everything.

Avis wrote:theoretically I suppose that would work. Bout 5 grand... if I find good deals on everything.

Not unless you find a complete donor vehicle. Sometimes the entire vehicle is cheaper than buying individual parts. Lets say this 92 Yukon's trans a t-case will work. $2300 OTD and you can sell whats left afterwards.

http://phoenix.craigslist.org/cph/cto/2020654932.html

I"d have to get a custom driveshaft built, find and buy a D-60, plus all the hardware to mount it.

Avis wrote:I"d have to get a custom driveshaft built, find and buy a D-60, plus all the hardware to mount it.

Oh you were saying 4-5 for everything? Well yeah that's expected. If you can find a list of transmissions that mate to you mighty 6.1 (?) liter you might want to then try to find a 4wd, solid front axle vehicle that has a trans off the list. It'd say thats better than parts shopping piece by piece.

Got your heart set on a 60? A high pinion D44 will go for about a quarter the price. It's worked for me so far. What about gearing? Gonna try to match the rear?
Have you considered your steering on the new setup?
What about the speed sensor for the speedo and ABS? Know where it/they are at? Does the truck have front ABS? Issues there. CEL's will automaticly fail you at emissions.
Gonna go with leafs or links? If links, radius arms, four link, three link with a panhard? What sort of lift will you need to clear the new setup? Gonna have to lift the rear as well to match.
Is this gonna be your daily driver? If so, road manners will be important, if not trail performance is obviously more important.
Just some quick thoughts.
I had to figure alot of this stuff out the expensive way after the project was well underway.

Chad wrote:Got your heart set on a 60? A high pinion D44 will go for about a quarter the price. It's worked for me so far. What about gearing? Gonna try to match the rear?
Have you considered your steering on the new setup?
What about the speed sensor for the speedo and ABS? Know where it/they are at? Does the truck have front ABS? Issues there. CEL's will automaticly fail you at emissions.
Gonna go with leafs or links? If links, radius arms, four link, three link with a panhard? What sort of lift will you need to clear the new setup? Gonna have to lift the rear as well to match.
Is this gonna be your daily driver? If so, road manners will be important, if not trail performance is obviously more important.
Just some quick thoughts.
I had to figure alot of this stuff out the expensive way after the project was well underway.

D44 would do just fine, and excellent point on being cheaper. Probably would match the gearing to the rear to save from re-gearing everything. So many questions! lol It would be my DD though, and I"d still tow with it as well. Probably will wait till I get the 93... then It can just be a trail rig

Avis wrote:then It can just be a trail rig

This

I like!