1989- RS to 4x4 swap list

10051 Views 74 Replies 12 Participants Last post by markmitch, 5 d ago

markmitch

Discussion Starter · Sep 12, 2020

My 89 Astro RS has had many modifications over the years and is close to being done (surprised?) so to keep me going I decided to buy an AWD frame and take it to the next level. I have a list and pictures of what I need and what I wish to do started and will post it here and as I purchase things I will add those pics too.
My ideas so far: Front awd frame from a newer Astro/Safari from pick n pull will be stripped at the yard and will cost approximately 100 bucks. Front axle from 1994 to 2004 S-10 Blazer with 4.3/5 speed trans (cast iron instead of aluminum) stock from suspension from same frame-no clue on cost yet., I will be using a 4x4 transfer from an S-10 cost is 180.00 pnp. I will need to get a 700R4 case somewhere to remove my guts into since my transmission is a fresh rebuild basically. I will post more info as I go.. This will be a slow process as money comes available. I already added steel rear springs and 11" drums so that is done. Left kit will come last. Thanks for reading, Mark

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kennethneil81

· #21 · Nov 5, 2020

markmitch said:
New (to me ) mirrors I got from another member-I figure they will be better for off roading since they are not all plastic.

@markmitch

Those mirrors look good on there. I will definitely be following your build.

Kenny

markmitch

Discussion Starter · #22 · Nov 5, 2020

Since I want to do a pressure test on my 700R4 transmission prior to beginning the disassembly of the 89 I drove it up on a set of ramps and climbed under it and sprayed everything that will have to come apart with pb blaster to make my life easier when I do start the process. Once the transmission situation is resolved I will start draining the fluids. Then pull the engine and transmission. Once I get that far I will slowly strip the frame I hope to reuse the brake lines from 89 on the 98 frame.

AstroWill

· #23 · Nov 6, 2020

Good luck Mark!

markmitch

Discussion Starter · #24 · Nov 7, 2020

I think once I find the adapter I need to use my transmission with the newer 4472 transfer I will only have one major hurdle left and that will be the brake lines. I am hoping I can reuse the factory lines from the 89 but I may have to make some and to be honest I have never done that. I have made fuel lines and transmission lines but that was a long time ago. I have atubing bender kit but my flaring tool is missing parts so I will have to either buy one or see if autozone has one I can rent. Mark

90safari

· #25 · Nov 7, 2020

markmitch said:
I think once I find the adapter I need to use my transmission with the newer 4472 transfer I will only have one major hurdle left and that will be the brake lines. I am hoping I can reuse the factory lines from the 89 but I may have to make some and to be honest I have never done that. I have made fuel lines and transmission lines but that was a long time ago. I have atubing bender kit but my flaring tool is missing parts so I will have to either buy one or see if autozone has one I can rent. Mark

The brake lines will be easy, as they are smaller and easier to bend (can be wrapped around a beer bottle). I replaced all of them on my 88 last summer, and just used sections of line and couplers, so I can replace just what I need in another 10 or so years.
I want to say the rear line was 3/16ths, while the front lines were 1/4 inch. At least they all use normal line fittings (no metric stuff mixed in). On mine, the section of line between the frame rail and the fuel tank was where the rear line rusted thru and leaked. I did the fronts, only because I had the rear open, and they looked a little crusty after 31 years.

markmitch

Discussion Starter · #26 · Nov 7, 2020

The lines on my 89 from what I can see are in good shape the problem I may encounter is using the original brake lines from my 89 on the 98 frame simply because the 98 frame is AWD and I am using the brake components on the front of the 98 with the 89 brake system. As you said I may have to make up new lines and such so getting all the adapters to make the two systems work together may cause me some grief.

markmitch

Discussion Starter · #27 · Nov 8, 2020

So another thing to post for future go getters wanting to do this: From the first gen van to the second gen vans the front bumper brackets are somewhat different. I had to use a hammer to get the brackets to line up for the top bolt holes I finally got them but the bottom holes are not the same as the 1st gen frame so I will have to re drill them. The side brackets seem to fit in the correct place but there are no bolt clips there so I removed them from the 1st gen van and added them to the 2nd gen frame. It got dark on me before I finished so I will finish tomorrow. The poly bushings I have on the front sway bar are the same size as the bar on the 2nd gen frame so I will swap them over tomorrow too.

markmitch

Discussion Starter · #28 · Nov 8, 2020

found the trans to transfer adapter on ebay cost with shipping $92.00

markmitch

Discussion Starter · #29 · May 20, 2021

Still thinking about the color I will eventually paint my van I was going blue then I thought about the OD green but after looking at some pictures online I decided to go a different direction: So what do you think about this idea? Mt van was a goldish color originally with the RS strip kit in black and red. (see pictures) SO what if I painted my van black and used gold for the stripes basically a reverse of what it was originally? Of course I will have to paint the stripes as I can not get the stripes new. Let me know what you all think of this idea? Anyone have a program or app to make it that way for me? picture is in my photo album and for some reason I can't bring it here?

sixsix

· #30 · May 20, 2021

markmitch said:
... Anyone have a program or app to make it that way for me? picture is in my photo album and for some reason I can't bring it here?

Haha

mark - sometimes it seems like you just joined the forum 3 weeks ago and had not had a chance to look around...

LumaWJ

· #31 · May 22, 2021

markmitch said:
Thank you for you info I did not know that about the 233. I am not really planning on an serious off roading but my house in New Hampshire has 10.5 acres and I would love to be able to drive around the property. in the summer I can actually cut trees down and make trails over to and around the island. If I build it strong there should be no problems doing this. So I will cut and paste your info and print it for my note book. Do you have 4lo with your set up?

233 is basicaly 231. Only difference I see is the motorshifter. I am Jeep guy and we are doing serious offroading and I have had Jeep ZJ 5.9 and Now I have Jeep WJ both were changed to NP231. Both cars have above 2400kgs because of all offroad rigs and the NP231 is running well without any problems. Older 231 had narrow chain They were used on Jeep XJ, YJ etc.
I also will put NP233 on my van with manual shifter. What we like here to use lever from Jeep liberty KJ which nicely fit to the floor and is done.

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Ironsides

· #32 · May 22, 2021

You must have image sharing turned off for that pic(?) but I've got some time to kill today, I'll throw it into my paintdotnet and see what I can do.

markmitch

Discussion Starter · #33 · May 22, 2021

Thanks guys I like the shifter picture, right now for about 2 to 3 weeks I am in California and my Astro is in New Hampshire so about all I can do it throw ideas out there to see what others are doing and make notes in my laptop for future things I can do to it. Mark

Ironsides

· #34 · May 22, 2021

Kind of quick, but helps you visualize.
Grabbed the original jpg.

2012-05-17 17-24-36 194.jpg

This is what I made so far

2012-05-17 17-24-36 194.png

I have the working file with layers, when I'm not helping across the street with my neighbor's boat, I'll have another look at it and/or if you want to change the colors.

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2

markmitch

Discussion Starter · #35 · May 22, 2021

Yeah I am now thinking of a gun metal gray with the black staying black but I have a year to figure it out lol. Thanks for the color change pictures.

Ironsides

· #36 · May 22, 2021

Time is always good to have on your side.

2012-05-17 17-24-36 194_grey_trim.jpg

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Ironsides

· #37 · May 22, 2021

Had to rethink that one LOL

2012-05-17 17-24-36 194_gray_body.png

Got kind of weird recoloring in grey, but it works for visualizing.

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Ironsides

· #38 · May 22, 2021

This is better.

2012-05-17 17-24-36 194_gunmetal.png

The recolor tool still effected by the original color, too much brown coming through, but it is better.

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Ironsides

· #39 · May 23, 2021

1 Year Later...

2012-05-17 17-24-36 194_gunmetal_recolor.png

After neighbor's boat work, I spent some more time on your van, worked better once I switched it to black & white, I was fighting red tones from original color. Then recolored the wheels, bumper, windows to look fresh.

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markmitch

Discussion Starter · #40 · May 24, 2021

cool thank you.Mark

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