Hello! This is my 4wd Conversion Project Thread. I've wanted to convert to 4wd ever since I found TNX Website, and while buying another truck is easier, building it yourself is a lot more fun! I'm also lifting my truck from 2" to 3-4" at the same time.
This thread will follow many of the same steps as what @USMMA11NC, @germandude890, and x_mods from clubfrontier did to convert their 2wd to 4wd, but I figured, more is better.
(Update 01/13/18:) Unfortunately, 'x_mods' thread did not survive the "Photobucket Ransomware Disaster".
First Off - The Parts List: (Note: I included the prices that I paid for reference if anybody else wants to do this conversion.)
Mod Group
|
Part Nomenclature
|
MFR & Part Number
|
QTY
|
Total Price
Front Differential
|
|Wheel Bearings/Hubs | Timken SP450701 | 2 | $271.16
|Front Axle Nut (32mm)|Nissan 40262-2Y00A|2|$4.60
|CV Axles|Nissan 39100-EA000|2|$50
|Front Differential (3.36)|Nissan 33100-EA33A|1|$400
|LOKKA locker|Lokka NIS-FO-61|1|$0 Was already in diff
|Differential Bracket LH|Nissan 50333-7S031|1|$21.92
|Differential Bracket RH|Nissan 50332-7S031|1|$21.92
|Differential Bolts|Nissan 54726-7S000|3|$16.02
|Differential Nuts|Nissan 08918-3442A|2|$3.44
|80W-90 (1-3/4 Qts)|Valvoline 831|2|$17.98
Front Driveshaft |
|Driveshaft|Nissan 37200-ZP90A|1|$61
|U-joints|Spicer 5-1310X|2|$42.26
|Front Driveshaft Bolts|Nissan 37120-4P00A|8|$14
|Front Driveshaft Nuts|Nissan 37171-7S00A|8|$10.40
Transmission |
|Transmission Assembly 4x4|Jatco RE5R05A|1|$847.00
|Transmission Filter/Gasket|ATP B-372|1|$14.34
|Front Oil Pump Seal|Nissan 31375-4AX02|1|$5.60
|Matic S (10-7/8 Qts)|Nissan 999MP-MTS00P|11|$95.50
|Washer Seals Oil Cooler Lines|Nissan 21626-32U00|4|$2.96
|Charging Pipe O-ring|Nissan 31084-20301|1|$3.40
|Charging Pipe Gasket|Nissan 31397-90X01|1|$4.32
|Charging Pipe Self-sealing Bolt|Nissan 31377-JL01A|1|$2.41
Transfer Case |
|Transfer Case Assembly|Nissan 33100-EA33A|1|$95.97
|Rear Seal | Nissan 33140-7S110|1|$13.59
|Rear Dust Cover | Nissan 33141-7S11A|1|$11.34
|Transfer - Transmission Bolts|Nissan 08124-0451E|14|$15.13
|Rear Insulator Mount|Nissan 11320-9CA0A|1|$112.14
|Matic D (2-1/8 Qts)|Nissan 999MP-AA100P|3|$29.25
Rear DriveShaft |
|Rear Driveshaft|Nissan 37300-ZP71A|1|$100
|U-joint|Spicer 5-1330X|1|$11.25
|Rear Driveshaft Bolts|Nissan 37120-0P00A|6|$7.92
|Rear Driveshaft Nuts|Nissan 37171-7S00A|6|$7.80
Rear Axle |
|M226 (3.36 - Elocker)|Nissan 43003-9CL0C|1|$700
|U-bolts|Pro-Comp 13-90334A|4|$51.96
|75W-140 (4-1/4 Qts)|Mobil 1 102490|5|$89.75
|Ballistic Fab Cover|Ballistic Fabrication DIF-2018-2|1|$110.50
|E-brake Shoes|Monroe BX869|1|$19.20
|E-brake Spring/Hardware Kit|Carlson 17400|1|$10.34
|Breather Nipple|Nissan 38323-C601A|1|$5.29
Misc |Wiring, Arduino...|||$126.3
|
Shipping ||||$558.28
Discounts |Amazon Gift Cards, Discounts through NORSE..|||$-408.16
|
Total ||||$3,608.95
My Truck has 80k miles
The Front Diff has approximately 70k
The 4wd Transmission has 15k
The Transfer Case and Rear Axle have approximately 100k
I chose to replace the Transmission Filter and Front Seal because LKQ's Warranty will be void if not replaced.
I also chose to replace the Rear Seal and Dust Cover on the Transfer Case because it was Duct taped together and has been banged up during shipping.
All other Seals look good so far.
EDIT: I recommend changing every single Seal while everything is out. They're cheap and much easier to change while component is off the Truck. I've had to replace the Front Output Seal on the Transfer Case and the Front Driver-side Diff Seal was leaking slowly as well. The $50 for all Seals was well worth not having to spend hours under the Truck later on.
I chose to replace the U-joints since its easier to do it before installing them, and they will need to be done at some point so might as well do it now with new ones.
Now for the Lift:
Mod Group
|
Part Nomenclature
|
MFR & Part Number
|
QTY
|
Total Price
Front Suspension
|
|Front Adjustable Shocks (5100)|Bilstein 24-187053|2|$193.34
|Coil Springs|Moog 81280|2|$62.12
|Top Rubber Spring Isolators|Nisstec N-UBK|2|$54.14
|Top Mount Rubber Bushings|Included with above|2|$0
|Steel Top Mount Sleeve|Included with above|2|$0
|Top Coilover Washers|Included with above|2|$0
|Lower indented Coilover Washers|Included with above|2|$0
|Shock Top Bracket|Nissan 56115-EA001|2|$22.67
|2" Spacers + Bumpstops|PRG prg-2lk-x|2|$0 Already on truck
|SPC UCA|SPC 25540|2|$350
Rear Suspension |
|Single AAL|Deaver D10045L09|2|$99.00
|Rear Shocks (5100 3-4")|Bilstein BE5-6253-H5
|Shims 4 degrees *** |PRG Xterra shim|2|$44.00
|Rear Shackles|PRG prg-shkl-x|2|$0 Already on truck
|
Shipping ||||$22.19
Discounts ||||$-49.98
|
Total ||||$937.86
I bought new Springs because the 2WD Springs are 0.4" shorter at rest and may have a different Spring Rate.
I bought new Top Hats and such because I figured I might as well replace the Bushings and also for convenience since I can assemble the Struts before touching my Truck.
***I originally ordered 3 degree Shims, but PRG sent me 4 degree ones, so we'll see if they do the job.
Below are pictures of the parts. The Rear Axle / Driveshafts are not pictured yet. I'll post those pictures when I have them.
It's heavy...
The Plan
Since this is my Daily Driver, I can't afford many days of downtime at once. I will do this conversion step by step when possible.
My Plan Currently Is To Do:
1- Transmission - Transfer Case - Rear Axle
2- Front Differential
3- Wiring
1-
Step 1 will be the biggest step. It will involve swapping the Transmission and Transfer Case in as well as the M226.
Since I'm 2wd currently, my C200k Flange only has 4 bolts. Since the M226 as well as the 4wd Rear Driveshaft have 6 bolts, I unfortunately can't run the new Transmission with my current Axle easily. This will also include installing the AAL in the Rear.
2-
The second step will involve welding the Differential Brackets to the Frame.
I will then tear apart the Front Suspension to install: The new 4WD Hubs, the 5100s, the SPC UCAs and the CV Axles.
I can then fill the Front Diff with fluid and Drive the Truck like that. It will still be in 2wd since no Driveshaft will be connected to the Diff just yet.
3-
This step will be the easiest since I already figured out how to control the Transfer Case without going trough any of the Factory Computers. I will post the Arduino Code once I test it in real life situations. So far I've only tested it with the Actuator out of the TC.
This will also include the wiring of various LED Indicators to ensure that everything is working properly.
I will also wire the Rear e-Locker in this step.
I won't have any progress for a few weeks since I'm going through finals and I'm still waiting on a few parts. I do have all the parts to complete Step 1 though.
If you see anything wrong / any part that I should have/replace that I don't have listed, feel free to let me know !
Thanks for reading
This thread will follow many of the same steps as what @USMMA11NC, @germandude890, and x_mods from clubfrontier did to convert their 2wd to 4wd, but I figured, more is better.
(Update 01/13/18:) Unfortunately, 'x_mods' thread did not survive the "Photobucket Ransomware Disaster".
First Off - The Parts List: (Note: I included the prices that I paid for reference if anybody else wants to do this conversion.)
|Wheel Bearings/Hubs | Timken SP450701 | 2 | $271.16
|Front Axle Nut (32mm)|Nissan 40262-2Y00A|2|$4.60
|CV Axles|Nissan 39100-EA000|2|$50
|Front Differential (3.36)|Nissan 33100-EA33A|1|$400
|LOKKA locker|Lokka NIS-FO-61|1|$0 Was already in diff
|Differential Bracket LH|Nissan 50333-7S031|1|$21.92
|Differential Bracket RH|Nissan 50332-7S031|1|$21.92
|Differential Bolts|Nissan 54726-7S000|3|$16.02
|Differential Nuts|Nissan 08918-3442A|2|$3.44
|80W-90 (1-3/4 Qts)|Valvoline 831|2|$17.98
Front Driveshaft |
|Driveshaft|Nissan 37200-ZP90A|1|$61
|U-joints|Spicer 5-1310X|2|$42.26
|Front Driveshaft Bolts|Nissan 37120-4P00A|8|$14
|Front Driveshaft Nuts|Nissan 37171-7S00A|8|$10.40
Transmission |
|Transmission Assembly 4x4|Jatco RE5R05A|1|$847.00
|Transmission Filter/Gasket|ATP B-372|1|$14.34
|Front Oil Pump Seal|Nissan 31375-4AX02|1|$5.60
|Matic S (10-7/8 Qts)|Nissan 999MP-MTS00P|11|$95.50
|Washer Seals Oil Cooler Lines|Nissan 21626-32U00|4|$2.96
|Charging Pipe O-ring|Nissan 31084-20301|1|$3.40
|Charging Pipe Gasket|Nissan 31397-90X01|1|$4.32
|Charging Pipe Self-sealing Bolt|Nissan 31377-JL01A|1|$2.41
Transfer Case |
|Transfer Case Assembly|Nissan 33100-EA33A|1|$95.97
|Rear Seal | Nissan 33140-7S110|1|$13.59
|Rear Dust Cover | Nissan 33141-7S11A|1|$11.34
|Transfer - Transmission Bolts|Nissan 08124-0451E|14|$15.13
|Rear Insulator Mount|Nissan 11320-9CA0A|1|$112.14
|Matic D (2-1/8 Qts)|Nissan 999MP-AA100P|3|$29.25
Rear DriveShaft |
|Rear Driveshaft|Nissan 37300-ZP71A|1|$100
|U-joint|Spicer 5-1330X|1|$11.25
|Rear Driveshaft Bolts|Nissan 37120-0P00A|6|$7.92
|Rear Driveshaft Nuts|Nissan 37171-7S00A|6|$7.80
Rear Axle |
|M226 (3.36 - Elocker)|Nissan 43003-9CL0C|1|$700
|U-bolts|Pro-Comp 13-90334A|4|$51.96
|75W-140 (4-1/4 Qts)|Mobil 1 102490|5|$89.75
|Ballistic Fab Cover|Ballistic Fabrication DIF-2018-2|1|$110.50
|E-brake Shoes|Monroe BX869|1|$19.20
|E-brake Spring/Hardware Kit|Carlson 17400|1|$10.34
|Breather Nipple|Nissan 38323-C601A|1|$5.29
Misc |Wiring, Arduino...|||$126.3
|
Shipping ||||$558.28
Discounts |Amazon Gift Cards, Discounts through NORSE..|||$-408.16
|
Total ||||$3,608.95
My Truck has 80k miles
The Front Diff has approximately 70k
The 4wd Transmission has 15k
The Transfer Case and Rear Axle have approximately 100k
I chose to replace the Transmission Filter and Front Seal because LKQ's Warranty will be void if not replaced.
I also chose to replace the Rear Seal and Dust Cover on the Transfer Case because it was Duct taped together and has been banged up during shipping.
All other Seals look good so far.
EDIT: I recommend changing every single Seal while everything is out. They're cheap and much easier to change while component is off the Truck. I've had to replace the Front Output Seal on the Transfer Case and the Front Driver-side Diff Seal was leaking slowly as well. The $50 for all Seals was well worth not having to spend hours under the Truck later on.
I chose to replace the U-joints since its easier to do it before installing them, and they will need to be done at some point so might as well do it now with new ones.
Now for the Lift:
|Front Adjustable Shocks (5100)|Bilstein 24-187053|2|$193.34
|Coil Springs|Moog 81280|2|$62.12
|Top Rubber Spring Isolators|Nisstec N-UBK|2|$54.14
|Top Mount Rubber Bushings|Included with above|2|$0
|Steel Top Mount Sleeve|Included with above|2|$0
|Top Coilover Washers|Included with above|2|$0
|Lower indented Coilover Washers|Included with above|2|$0
|Shock Top Bracket|Nissan 56115-EA001|2|$22.67
|2" Spacers + Bumpstops|PRG prg-2lk-x|2|$0 Already on truck
|SPC UCA|SPC 25540|2|$350
Rear Suspension |
|Single AAL|Deaver D10045L09|2|$99.00
|Rear Shocks (5100 3-4")|Bilstein BE5-6253-H5
|Shims 4 degrees *** |PRG Xterra shim|2|$44.00
|Rear Shackles|PRG prg-shkl-x|2|$0 Already on truck
|
Shipping ||||$22.19
Discounts ||||$-49.98
|
Total ||||$937.86
I bought new Springs because the 2WD Springs are 0.4" shorter at rest and may have a different Spring Rate.
I bought new Top Hats and such because I figured I might as well replace the Bushings and also for convenience since I can assemble the Struts before touching my Truck.
***I originally ordered 3 degree Shims, but PRG sent me 4 degree ones, so we'll see if they do the job.
Below are pictures of the parts. The Rear Axle / Driveshafts are not pictured yet. I'll post those pictures when I have them.
It's heavy...
The Plan
Since this is my Daily Driver, I can't afford many days of downtime at once. I will do this conversion step by step when possible.
My Plan Currently Is To Do:
1- Transmission - Transfer Case - Rear Axle
2- Front Differential
3- Wiring
1-
Step 1 will be the biggest step. It will involve swapping the Transmission and Transfer Case in as well as the M226.
Since I'm 2wd currently, my C200k Flange only has 4 bolts. Since the M226 as well as the 4wd Rear Driveshaft have 6 bolts, I unfortunately can't run the new Transmission with my current Axle easily. This will also include installing the AAL in the Rear.
2-
The second step will involve welding the Differential Brackets to the Frame.
I will then tear apart the Front Suspension to install: The new 4WD Hubs, the 5100s, the SPC UCAs and the CV Axles.
I can then fill the Front Diff with fluid and Drive the Truck like that. It will still be in 2wd since no Driveshaft will be connected to the Diff just yet.
3-
This step will be the easiest since I already figured out how to control the Transfer Case without going trough any of the Factory Computers. I will post the Arduino Code once I test it in real life situations. So far I've only tested it with the Actuator out of the TC.
This will also include the wiring of various LED Indicators to ensure that everything is working properly.
I will also wire the Rear e-Locker in this step.
I won't have any progress for a few weeks since I'm going through finals and I'm still waiting on a few parts. I do have all the parts to complete Step 1 though.
If you see anything wrong / any part that I should have/replace that I don't have listed, feel free to let me know !
Thanks for reading