AWD Conversion How-To

[ThumpinZ]

sweet if i no longer used my truck for work and haulin crap around I'd jump all over this, until then if you remove a 373 front diff please send them to Sharpsburg Ga ;o) I have a habbit of b eakin them

[PitchBlackC3]

I've done it this way lots of times. Not for an AWD swap, but for temp 4x4 fix.
You can put in a spacer that keeps the axle engaged or leave the actuator in the extended position. Pre-97 OBS with the thermal actuator you will have to put in a spacer, the thermal actuator retracts when power is removed. The 97-later will retain its position until power is applied again.
The only difference in the AWD and 4x4 axle is the 4x4 axle is 2 piece on the right side and can be engaged/disengaged by the collar sliding and connecting/disconnecting the 2 pieces. In fact I am running a OBS 4x4 front diff in my C3 with the AWD right side housing exstension and axle shaft from the C3. My front diff was groaning and I had a OBS front diff in my shop that was the correct ratio, so I am using it.

[Mang213]

thats good info, thanks for posting up

[GnatGoSplat]

Great thread, I'm considering to do this conversion. Do I need a new front driveshaft if I reuse the original 4x4 front diff? How can I tell if I need a new rear driveshaft? My truck currently has the thick aluminum one.
Did you use a transmission jack to lift the transfer case into position, or did you muscle it in?

[zeake]

Great thread, I'm considering to do this conversion. Do I need a new front driveshaft if I reuse the original 4x4 front diff? How can I tell if I need a new rear driveshaft? My truck currently has the thick aluminum one.
Did you use a transmission jack to lift the transfer case into position, or did you muscle it in?

Your front shaft should be fine either way. The rear shaft will need to be changed because the case on the nv149 is a different legth than the 4x4 case. I use a combination of floor jack and muscle and extra hands. If your truck is extended cab a ss rear drive shaft will work.

[GnatGoSplat]

Thanks for the reply. In your pics, it looks like the SS front shaft is shorter. Would I be able to reuse the front shaft because the 4x4 front diff is shorter?

[zeake]

Thanks for the reply. In your pics, it looks like the SS front shaft is shorter. Would I be able to reuse the front shaft because the 4x4 front diff is shorter?

I am not sure which is shorter or longer. Using a 4l60e you will need the ss shaft. Using a 4l80 you need the factory 4x4 shaft your truck came with.

[GnatGoSplat]

I have the stock 4L60E and manual transfer case. Does that mean I need to replace both front and rear shafts?

[zeake]

I have the stock 4L60E and manual transfer case. Does that mean I need to replace both front and rear shafts?

I have no info on the drive shafts for the manual transfer case. Sorry but I have no clue. I would at least count on replacing the front shaft.

[budhayes3]

Great write-up man, I'll be following this one day. I'm 4x4 with the autotrak transfer case, and my front diff is already toast, my G-80 stopped working, and I want to go from 3.73's to 4.10's, so I'm gonna go with the complete front diff like you did, and see what I can do about getting a good used or rebuilt transfer case...gonna take a while to get the dough though...