I own a 97 2500 chevy ext cab long-bed 2wd pickup. I was wondering if anyone knew of a straight axle 4x4 swap kit. I'm a 12 year G.M. dealer drive line-specialist, and allready have a 205 transfer case  and a dana 60 front diff, I have the skills and most of the parts to do this. I also have machining experience as well, so I could fab it up my self if I have to, however if there was a kit allready out there I'd rather do that instead.

I know ORU has a kit to straight axle swap, but it says its just for the IFS 4x4. Dose anybody know if it will work on the 2 wheel drive frame as well? Don't tell me to just buy a 4x4, because my truck is paid for. I would appreciate any help with my project.

Thanks

You are the GM tech dude! Dig up the specs for both trucks (4x4 and 2wd), and find out.

The rest of us ask questions like this for folks like you to answer! 

 I have the specs for the stock stuff, however I wanted to know if anyone made an aftermarket kit ! I've never swaped in a straight axle into a 88-2000 2 wheel drive truck.

The frt section of the frames for 2 wheel drive and 4x4 are different, and a 2500 frame is a little different than a 1500, it's based on a 3500 frame, with spring load ratings the main difference in the two.. That's why I posted.

 You guys have more experience with aftermarket stuff. At the dealer we deal mostly with OEM bolt ons and repairs, which obviously this swap isn't. The shop rate is usually too expensive for most people to have us do custom work, plus we get paid flat rate, which means by the job, not the hour. So most of the time we wouldn't take in this kind of work anyway, seeing as there is no pre-set time to do the job.

Again any info to lead me to the right company, or tell me no one makes one, would help me decide if I would have to fab it up myself (which would be more expensive ) or if I could buy a kit.

Thanks

ORU, http://www.offroadunlimited.com/ProductCart/PC/mainIndex.asp

Pretty much the solid axle swap guru's. They do mostly 4x4 IFS to SFA work though. Get in touch with them and get some kit specs.

Good luck.

He already knew about ORU boss. sice you already have a 2wd trannie, you may want to look for a divorced mount t-case, it will help with driveshaft angles. You will need to create a custom crossmeember but it will be worht the effort. If its a married 205 you will need to swap tailshafts and match spline counts. As fare as the hangers, I have seen some guys use the older stock chevy stuff. Just need to figure out what length spring you want and then install the hangers and shackles to fit. How big are gonna go?  

 I'd like to fit anywhere between, a 37 and 39" tall tire, so I'm hoping with a 6" lift and maybe a 2" body lift it would work. I'm not much into body lifts, but I don't want to go too crazy with suspension. Even though it is a very long truck I don't want it to feel like it wil tip over easy. I have built a couple of swamp buggys back when I lived in Florida by the Evergaldes. They all had 44 to 55" farm tractor tires on them. The difference is you towed them to the swamp, you didn't have to drive them on the road to get where you wanted. They also would be relatively slow, 50 mph max, which I guess was good because they had no brakes ( the swamp mud would make them useless in about 2 minutes anyway).As I've said, the mechanics of it are no big deal, I'm just trying to get the suspension figured out!

I did call ORU and they don't have a kit for the 2wd to 4x4 drive, and told me they don't know of anyone else either. What model yr earlier hangers have you seen used. 70's to 80's, or the 60's. I would really apreciate your help.

Thanks

Pre 88 hangers, shackles should probably be custom to fit the springs you decide to get. 6" springs should be plenty to clear 37's. You will need offset rims cause tof the kickout in the frame. Since your doing all this work, I would probably recommend against a body lift. Get a hold of a custom spring comapny like Deaver, and they will set you up.  

the best forum for chevy info I've found is www.67-72chevytrucks.com

There are at least a few dozen very active members, many are very knowledgable, some are professional auto mechanics. They have separate forums like "Engine and Drivetrain" and "4x4" as well as model specific forums like "88-98 GM" "73-87 GM" etc.

Good luck!

Hi, Ive done this myself. If you want an indepth explanation of what your up against email me at hp73chevy@yahoo.com.

The ORU kit will work, its not the 2wd or 4wd thats the issue, its finding an axle that has spring pearches that will fit your frame rails. If you have the right D60 the pearch width should be approximately 32.5 inches.  If that measures up, your golden.