THenningsen said:
I understand the differences in suspension but I was told that a 2wd frame is different than a 4wd frame. To fab a dana 60 under a 2wd truck they said was not secure because the frame wasn't meant to hold it. Is this true? I hate to sell my truck and would love to throw an axle under the front end and call it a 4wd ( i know it's not that easy). Any thoughts.
Altering the frame on your truck for this is not worth it, it is too much work. It will end up being a deep money pit after all the effort/time/funds you will have in the end. Most viable alternative is a 4wd donor vehicle frame or trade it in.
The odds of finding all the parts in good working order from a salvage yard are not really good compared to just biting the bullet and trading it for a similar year 4wd truck.
I have found numerous donor trucks that are 4wd for drivetrain parts, but they usually have damaged frames. This is going to be the hard part to find.
I have done things like you're talking about just for the sake of the project and for winter time boredome, but it is hardly ever cheaper than just moving on to another vehicle.
If you are mechanically able, you could always locate a similar truck to yours with 4wd and then pick the better parts of the two to build a keeper truck and a selling truck. It takes money to do this, something most folks who ask this question don't have
What chassis type is your truck? long bed? short bed? extended cab? regular cab? Might be able to locate an auction truck with a blown motor etc. but you'll need the 4wd transmission, transfer case, front axle, driveshaft. These will add up unless you find a good useable donor.