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99 Astro 2wd > 4x4 build

1518 Views 13 Replies 6 Participants Last post by  Maximan1
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I've read all the posts about how the best way to convert a 2wd Astro to 4x4 is to
Park your RWD van on level ground, open the gas cap door.

Remove the gas cap.

Drive the van about 2-3 car lengths forward.

Drive an AWD van into it's previous place.

Install gas cap on new AWD van.
But when I tried to remove my gas cap, I found that it was tethered to my van! So I went to the junkyard and started the next best thing.

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The willing donor

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I've had my Astro for a little while now, and ever since I lifted it I wished that I had gotten an AWD one. AWD Astros are ridiculously expensive in my area so I just kept on waiting.

Got the full rust free SoCal subframe from a 99 Astro AWD, 2 days after it showed up in my local junk yard. I still need to collect some more parts, but soon my van will be a true 4x4.

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Transplant recipient.

I will post updates to this thread.
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I put a 98 AWD frame under my 89 RS. Should be on the road soon.
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I will post updates to this thread.
YES! Please do post often.
Rod J
Issaquah, WA
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GREAT
Does anyone know if the 99 Astro AWD vans has caliper brackets? Someone had already swiped the calipers from the subframe - I was able to find rebuilt calipers pretty readily but have not found caliper brackets anywhere.

Also does anyone have experience with the poly subframe mounts? They are significantly cheaper (at the moment) but I'm afraid they would transmit way too much road noise and vibration.
That's a nice looking van. It's going to be sweet when you're done.
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I've got some parts in the mail. My 4x4 output shaft, transfer case adapter, and NP233c transfer case are all here. Once the scrapyard picks up the engine and interior donor car I bought for my girlfriend (her Isuzu Rodeo developed a nasty rod knock), I should have enough to buy all the remaining parts for my subframe swap in one fell swoop.

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I'm getting excited, even got a custom emblem designed. Going to be getting a few of these 3d printed out soon.

Wood Font Art Auto part Metal

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Well the transmission has started exhibiting signs of failure, so I am getting ready to pull it out and have it rebuilt. Since I will be getting it rebuilt, I will have the shop swap the output shaft. Then I will be able to get the subframe swapped over as well, and bolt up my transfer case.

I did also purchase a parts van, mostly for the door seals, grill + lights, and the 3.73 G80 rear end. This does mean that I need to find a 3.73 from diff instead of the 3.42 front diff that I have currently. This does mean that I have a plethora of parts available for now, including the base for my custom built high roof. If anyone needs any parts, let me know now - I will not keep the parts van for long - just long enough to swap over the stuff I need, cut out the sheet metal I need, and move it along.





It even came with an original Astro cassette tape, and it works in the original tape deck.

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G80 is out of the parts van and in my van now!





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Nice job...any 'surprises' along the way?
I used car-part.com to locate a local source for a 'spare' 3.73 front diff. It came out of an S-10, so I may have to swap a driveshaft flange if I ever install it. Being only an hour away and the price was very reasonable, so I could not pass up the opportunity.
Rod J
Issaquah, WA
No real surprises luckily. The parts van had some nasty rock hard undercoating all over it, so some of the smaller bolts were a bit harder to remove, but all went smoothly.

I drained and refilled the G80, swapped over the diff cover from my old differential. Just under 2 quarts of Royal Purple 75w90, new diff cover gasket. Almost done with the swap, just need to bleed brakes and tighten up the u bolts.

I'm looking at S10 from diffs also. To swap the flange is it a big job? I am assuming there is a crush washer, but I am not prepared to set up gear lash and such.
Are you in the San Diego area? Id like to take a look at this since im running into the same problem with high prices for AWD vehicles that are pretty trashed.
I am in north OC, couple of hours north of you. Once I finish I planned to go camp out in Anza Borrego, but currently the van is not driveable, nor does it have the AWD subframe installed yet.
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Well, I spent about 4 hours after work and pulled the trans out. Nice thing about the 4" lift is I didn't have to jack up the van to get the transmission out. I have the 4x4 output shaft and transfer case adapter ready to go. I'll be delivering this trans to the shop next week, after they finish with the rebuild the 4x4 conversion fun can really start.



If anyone wants to see the video of the not-so- spectacular failure of my 4l60e, I can post it. Tried to do a burnout to see if the G80 was working, ended up with all neutral forward gears. Still has reverse though!
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