* Transfer Case: You'll need a transfer case compatible with the 4L60E and your chosen front axle. This means sourcing a used case (often from a wrecked 4WD truck of the same year and engine), and ensuring it's in good working order.
* Front Axle Assembly: This is a significant expense and effort. You'll need a complete front axle assembly, including:
* Axle shafts
* Differential
* Hubs
* Brakes
* Steering knuckles
* All associated mounting hardware
* Driveshafts: You'll need two new driveshafts: one to connect the transfer case to the front axle, and potentially a modified rear driveshaft depending on the transfer case and its length.
* Crossmember: The frame likely needs a new crossmember or modification to accommodate the transfer case.
* Wiring Harness: The 4WD system requires additional wiring for the transfer case motor (if it's electrically shifted), 4WD indicator lights, and potentially other sensors.
* Control Modules: You might need to reprogram or replace the PCM (Powertrain Control Module) to recognize and control the 4WD system. This is often overlooked and can lead to major headaches.
* Mounts and Brackets: Numerous brackets and mounts will be needed to properly secure the transfer case, driveshafts, and front axle.
In short: This isn't a weekend project. It requires significant mechanical skill, welding experience (likely), access to specialized tools, and a substantial budget for parts. The cost of parts alone could easily exceed the value of the truck, depending on the availability of used parts and your labor costs.
Alternatives to Consider:
Before embarking on this complex conversion, consider these alternatives:
* Buying a 4WD Truck: This is often the most cost-effective and less time-consuming solution.
* Selling your 2WD and using the proceeds to buy a 4WD: This may be a more practical choice.
Recommendation: Unless you possess extensive mechanical experience and are comfortable with complex automotive repairs, this conversion is strongly discouraged. The potential for mistakes and unforeseen complications is high, leading to potentially significant costs and a possibly unreliable vehicle. Seek professional help from a qualified mechanic specializing in automotive conversions if you decide to proceed.
