Swapping Van Bodies

[b00duh]

Question for you guys, I tried searching but couldn't find anything that really describes what I'm thinking about doing.

I currently have 2 vans, one is a '94 safari xt awd and the other is a '92 safari xt rwd with a towing package. The rust on the '92 is really bad; the body is pretty much done on it because the rockers are totally eaten away. But, mechanically the van is in pristine condition and the whole frame and subframe have been coated to prevent rust. The '94 is starting to rust away but it is easily manageable by myself. Unfortunately, the awd system on the '94 is toast and I'm sitting on the fence on whether to rebuild the transfer case or not. So, I've been thinking about swapping the van bodies from one van to the other and putting in an lsd on the '92.

Anyone know how hard of a process would it be to swap van bodies?

[CopperFiremist]

Swapping out the sub frame can be done with a Cherry picker roll your subframe out and roll your another one in.

[b00duh]

I was thinking of going that route as well, but I was worried about the awd rear end mating with the rwd drivetrain. From what I've read, I would need to swap those as well since I was thinking of putting an lsd in the rear.

[CopperFiremist]

You might have to do a two step process.

[chevymaher]

I was thinking of going that route as well, but I was worried about the awd rear end mating with the rwd drivetrain. From what I've read, I would need to swap those as well since I was thinking of putting an lsd in the rear.

Use the driveshaft to the subframe donar. You got 2 drive shafts one for a awd and one for rwd. Use the rwd shaft and it bolts right up. They just 2 different lengths.

[markmitch]

I agree swap out the complete front frame assembly and the drive shaft from the 92 to the 94, check the gear ratios in both and pick the best one for your needs and swap the rear axle later if needed. However I recommend if you have the room to keep the AWD front frame , drive shaft and rear axle in case you wish to go back to AWD in the future.

[b00duh]

Thanks for all the information guys. I'll do the front frame swap from the looks of it. I'll take a bunch of the newer parts from the '94 that I recently installed and put them on the donor engine. I'll leave the rear end intact for now but swap later once I get the parts for the lsd installed. I know that I will need that rear end at some point since I tow my trailer quite often and it is a little on the heavy side since it's the rear half of an old dodge pick-up. Lol.

[97cargocrawler]

Why swap sub-frames? Swapping bodies sounds easier and more fun.

[Astrofarian]

LSD? Even here in Manitoba, that stuff's illegal no matter WHERE you're sitting. I checked (30 years ago, mind you lol)
Gen 1 vans are pretty cheap....is it worthwhile to do what you're thinking of? The van, NOT the LSD!!
-Mike-

[markmitch]

funny you should say that Mike cause I wondered what that meant too, then I realized what he was saying LSD= limited slip differential) lol good call to keep the second rear axle to rebuild later I wish I kept the one I had for the same reason but at the time I was prepping to move across country and never even thought about it.

[b00duh]

Why swap sub-frames? Swapping bodies sounds easier and more fun.

That's what I was thinking with this project. Disconnect anything connected to the body of the van, lift it off with my work forklift, then swap frames with the drivetrain all connected. Button it all back up and hope for the best. Lol.

LSD? Even here in Manitoba, that stuff's illegal no matter WHERE you're sitting. I checked (30 years ago, mind you lol)
Gen 1 vans are pretty cheap....is it worthwhile to do what you're thinking of? The van, NOT the LSD!!
-Mike-

I agree, they are cheap but a lot of them I've seen are rusted out. Is it worth it financially? Nope, just like any other vehicle project I've owned it just isn't. Cars are the worst things to sink money into. Lol. But is it enjoyable to do? Absolutely.

I figure, the awd is already toast so to replace or rebuild that is already a couple hundred to a couple thousand. But, with the body in decent shape I can do the body work and swap out the rusted out body on the rwd and call it a day. Sure, I lose the awd but a limited slip in the rear end will somewhat make up for it. Plus, I don't have to worry about the torsion bars in the front, which for some reason freaks me out that they will snap at some point while I'm driving. Lol.

[markmitch]

actually you will most likely need to swap the pcm and possibly the wring harness too, depending on the years cause the AWD is computer controlled isn't it?

[b00duh]

actually you will most likely need to swap the pcm and possibly the wring harness too, depending on the years cause the AWD is computer controlled isn't it?

No, it isn't computer controlled. It's mechanical...I believe it's a borg warner 4472 on the '94.

[kennysmoke]

Why swap sub-frames? Swapping bodies sounds easier and more fun.

That's what I was thinking with this project. Disconnect anything connected to the body of the van, lift it off with my work forklift, then swap frames with the drivetrain all connected. Button it all back up and hope for the best. Lol.

LSD? Even here in Manitoba, that stuff's illegal no matter WHERE you're sitting. I checked (30 years ago, mind you lol)
Gen 1 vans are pretty cheap....is it worthwhile to do what you're thinking of? The van, NOT the LSD!!
-Mike-

I agree, they are cheap but a lot of them I've seen are rusted out. Is it worth it financially? Nope, just like any other vehicle project I've owned it just isn't. Cars are the worst things to sink money into. Lol. But is it enjoyable to do? Absolutely.

I figure, the awd is already toast so to replace or rebuild that is already a couple hundred to a couple thousand. But, with the body in decent shape I can do the body work and swap out the rusted out body on the rwd and call it a day. Sure, I lose the awd but a limited slip in the rear end will somewhat make up for it. Plus, I don't have to worry about the torsion bars in the front, which for some reason freaks me out that they will snap at some point while I'm driving. Lol.

Ok... maybe I'm missing something here? Isn't everything other than the front subframe a unibody? There isn't a full frame the whole length of the van... right? So isn't swapping out the subframe and complete drive train the only real option?

[markmitch]

I agree

[b00duh]

Okay, so the weather finally let up and had time to check over the parts van and realized that it has the GT4 and G80 rear end. With it being a '92 and my awd being a '94 I know that they are both Gen 1 vans, so I'm assuming the subrames and rear ends would swap out easily or am I having to deal with the headache of having to change things since I'm thinking of switching from awd to rwd? I know that I will have to use the driveshaft from the rwd setup.

From what I've read on some posts, it looks like the steering linkage are different lengths...is this correct?

[Lumpy]

... or am I having to deal with the headache of having to change things...

You're swapping an entire body onto the subframe/engine of another van. I hardly think I'd consider something like a steering intermediate shaft to be a "headache". Certainly swapping drive shafts is simple.

Look at it like you now have the OPPORTUNITY to replace/rebuild small and inaccessible parts and assemblies that you can reach and optomize. Motor mounts, oil pan, water pump, rear main seals, all the stuff that is pretty difficult to reach while the van is intact. THAT kind of stuff is what I'd consider to be headache provoking.


Lump

[b00duh]

Sorry, I should have worded that a little more accurately. What I was meaning is there any custom fabrication I would have to undergo with the body. The engine on the '92 was freshened up last year with a new thermostat, fuel pressure regulator, new spark plugs, new spark plug wires, distributor cap, oil and cooler lines, etc. The only thing that hasn't been freshened up on the '92 was the front suspension, so I was going to freshen that up along with all mounts.

[redfury]

You might have to swap the link from the steering column to the gearbox, but it does have some play in it...you may not have to worry about it. It's going to have to be disconnected from both vans anyway though, so I'd just take them both off and measure each...use the one that makes the most sense. Don't forget to mark the location so you don't have a crooked steering wheel.

[b00duh]

You might have to swap the link from the steering column to the gearbox, but it does have some play in it...you may not have to worry about it. It's going to have to be disconnected from both vans anyway though, so I'd just take them both off and measure each...use the one that makes the most sense. Don't forget to mark the location so you don't have a crooked steering wheel.

Thanks, Redfury. I'll make sure to do that.