AWD conversion questions, anyone know?

I have an '03 GMC Savana G-2500 (standard wheelbase). I want to do an AWD conversion. I realize this is considered a major job, but I like a challenge and do a lot of mechaincal work.

I was told the driveline from an Astro AWD is the same, can I use the parts from that vehicle? Or perhaps I can find a wrecked Express and transfer the parts?

Any help is appreciated. Thanks!

AWD drive is not for a G-2500.
Do you mean 4W drive?

There used to be some companies that make part-time 4 wheel drive conversions on full size vans, usually for commercial and fleet customers like electricity utility companies, etc.
Occasionally such conversion vans come up for sale on the used market.

IMO it's better to get one of these than to try and engineer your own conversion.
Then you can drive the 4wd van or just use it for parts to convert yours.
Even that is a big job to do.

I am aware the G-2500 did not originally have AWD (or 4 wheel drive, however you want to refer to it), but as I said, I am looking to add the needed componemnts to make it AWD. I will have to find an AWD van and see what's needed.

It can't be that hard, transfer case, diff, a-arms and hubs....whatever I need. Just wanted to know if anyone had any onfo on it, or if the Astro components were interchangeable.

I am aware the G-2500 did not originally have AWD (or 4 wheel drive, however you want to refer to it), but as I said, I am looking to add the needed componemnts to make it AWD. I will have to find an AWD van and see what's needed.

It can't be that hard, transfer case, diff, a-arms and hubs....whatever I need. Just wanted to know if anyone had any onfo on it, or if the Astro components were interchangeable.
Just to clarify, AWD (all wheel drive) and 4 wheel drive are different concepts. Typically it is the transfer case design that makes the difference.

AWD are full time systems. where all 4 wheels are driven all the time. They have a differential gear system that allows the front and rear driveshafts to turn at different speeds, allowing the vehicle to go around corners.

4 wheel drive systems are more simple. These systems have the front and rear driveshafts turning at the same speed and are intended only to operate on loose or slippery surfaces. Typically, one axle (usually the front) is disconnected for travel on pavement.

The Astro van is a completely different design from your van and is based on the compact Chevrolet pick up truck platform. Your van is significantly larger, longer and wider than the Astro van, so the Astro components like the control arms, steering knuckles, driveshafts etc will not fit. Your transmission will not accept a transfer case, so you have to get a AWD transmission and transfer case combo. The AWD Astro transmission and transfer case will physically bolt up to your engine, but lots of details, like a fabricated transmission mount, wiring harness, shift linkage and driveshafts would have to be worked out.

As for the front end, the simple conversions involved removing all the original front suspension pieces, wheels, brakes etc and welding in front leaf springs and installing a solid front axle from an old 4WD pick up truck, then adapting the steering, brakes driveshaft and shocks to fit.

This set up works but the ride and handling are not as good as the stock set up.

I think your van has the option for an independent 4WD suspension set up but this is more costly and complex than the solid front axle approach.
As I said earlier, there are companies that make such conversions. They would be a good place to start for info to convert yours.
http://www.factory4x4vans.com/
http://www.youtube.com/watch?v=nEbmZDlqYc8

just my 2:2cents: ,but they do make an AWD Gvan,they made them from 2003-2009. plus the astro van is a unibody,the Gvan has a full frame.the G van is a G/H platform and the astro is an M/L platform.it would actually be easier to by a wrecked AWD G van of just by an AWD G van then it would to try and convert it.I would also agree with magicrat this is alot of work.

Thanks guys, very helpful and appreciated.....I found a few AWD vans, going to just purchase one and sell mine....mush easier in the long run. Thanks again forf all your input!

And remember AWD is 4W all the time,

4W drive is 4W when you need it and is switched to 2W when not needed.

Good choice on just buying one.

I have an '03 GMC Savana G-2500 (standard wheelbase). I want to do an AWD conversion. I realize this is considered a major job, but I like a challenge and do a lot of mechaincal work.

I was told the driveline from an Astro AWD is the same, can I use the parts from that vehicle? Or perhaps I can find a wrecked Express and transfer the parts?

Any help is appreciated. Thanks!


Did you ever convert your van>?

check this link out

http://www.expeditionportal.com/forum/threads/52911-Chevrolet-Express-Van-AWD-to-4x4-conversion