luthj
Engineer In Residence
Greetings and happy new year.
After pursuing several other avenues, I have narrowed in on a 4WD conversion approach for my 2004 T1N sprinter. The Sprinter presents some unique challenges. It is a unibody, and uses McPherson strut front end. Instead of coil springs, it uses a transverse leaf spring built into the subframe.
My goals were as follows.
I have done some initial rough modeling, and it is looking quite promising. I will use laser/plasma cut steel plate to fabricate a bolt-on subframe. This will accept a complete GM front suspension (without upper A-arm and shock).
Ride height will be 2" taller than stock. The sprinter steering rack will be retained, and moved up and forward. Tie rods will be custom, or use adapters for the GM joints.
What about the upper A-arm? Well I am planning on modifying the GM spindle/knuckle to bolt to the sprinters strut. The upper BJ stub will be cut off, and a bracket with camber adjustment and standoff studs will be welded on.
The GM IFS has a smaller distance between the wheel mounting flanges than the sprinter. So there should be enough room for a wheel adapter to the sprinters bolt pattern without changing the track width much from the ~65".
As far as gear ratios my sprinter is 3.725, the common GM 3.73 gears should work great. The other common sprinter ratio is 4.11, which is also common on GMT-800s.
I plan on using the GM torsion bars, and aft torsion bar member. Riser brackets will be used to attach the torsion bar anchor to the sprinter.
For the Tcase I am looking at a married NP242 or similar. The sprinter uses the NAG1/WA580 trans. My plan is to swap the sprinter internals to a jeep main case and adapter housing. (same as 2012+ wranglers).
Other random changes. The fuel tank will like need to move back 6" or a bit more. New tone rings/bands will likely need to be made and attached to the inner CVs. The sprinter uses 44 tooth rings. I think the GM hubs use 55 tooth, but have not confirmed.
After pursuing several other avenues, I have narrowed in on a 4WD conversion approach for my 2004 T1N sprinter. The Sprinter presents some unique challenges. It is a unibody, and uses McPherson strut front end. Instead of coil springs, it uses a transverse leaf spring built into the subframe.
My goals were as follows.
- Easy to source parts strong enough for a 9klb vehicle
- Minimal or no modifications to the unibody
- No custom wear parts
- Minimal machining work
- Stock handling and ride
I have done some initial rough modeling, and it is looking quite promising. I will use laser/plasma cut steel plate to fabricate a bolt-on subframe. This will accept a complete GM front suspension (without upper A-arm and shock).
Ride height will be 2" taller than stock. The sprinter steering rack will be retained, and moved up and forward. Tie rods will be custom, or use adapters for the GM joints.
What about the upper A-arm? Well I am planning on modifying the GM spindle/knuckle to bolt to the sprinters strut. The upper BJ stub will be cut off, and a bracket with camber adjustment and standoff studs will be welded on.
The GM IFS has a smaller distance between the wheel mounting flanges than the sprinter. So there should be enough room for a wheel adapter to the sprinters bolt pattern without changing the track width much from the ~65".
As far as gear ratios my sprinter is 3.725, the common GM 3.73 gears should work great. The other common sprinter ratio is 4.11, which is also common on GMT-800s.
I plan on using the GM torsion bars, and aft torsion bar member. Riser brackets will be used to attach the torsion bar anchor to the sprinter.
For the Tcase I am looking at a married NP242 or similar. The sprinter uses the NAG1/WA580 trans. My plan is to swap the sprinter internals to a jeep main case and adapter housing. (same as 2012+ wranglers).
Other random changes. The fuel tank will like need to move back 6" or a bit more. New tone rings/bands will likely need to be made and attached to the inner CVs. The sprinter uses 44 tooth rings. I think the GM hubs use 55 tooth, but have not confirmed.