The best place for you to start is have another daily driver. Also go look at either a 250 of 350 4x4 or better yet have one available to look at when your working. Then jack the frame up and put is on some very safe blocks of wood, the engine will be putting ALOT of weight on the jackstands when placed behind the suspension hangers. take off all you suspension, springs, traction arms, axles, and sway bars. Then spend about a half day cutting off the brackets with a grinder, I wouldn't use a torch because it will make the rivets hard to drive out. then go get measurements off another 350 4x4 to place the rear spring hanger brackets. then weld on those brackets its very important to have proper welds if you didn't already know that. then I put on the springs with the factory shackles bolted on and held them up with a jack. the frame is the same width as a 4x4 but doesn't have the holes and boxed frame in the front to bolt in front shackles so I took 2 peices of 1/2" x 3" flat iron with the proper bolt holes and welded them too each side of the frame rails, by the way you will need to have the bumper off to do this. then bolt up the spring and repeat on the other side. I welded on the shock towers the track bar bracket on the truck was homemade because i didn't have one, my suggestion is go find one and bolt to the crossmember. the steering you will need to get off of a 4x4 350, it bolts right on. your rear end also gets lifted 4" to be at 4x4 350 height.
The transfer case is not a complicated set up but is hard to explain but basically i made two L-shaped brackets that ride on top the frame rails to drop the case low enough to just clear the cab floor by maybe 1/2". the case is about 12" away yoke to yoke, to couple the tranny and t-case I took 2 slip yokes and cut about half the splines off 1 of them slid in the right length of splined shaft welded it then the other yoke slides on the other end making one side solid and one slide a slip. the front and rear shaft I then cut to length you will probably have to drop the carrier bearing to get the rear shaft straight. I was able to use the 2wd cross member but depending where the case ends up it may not clear. the np 205 is bullet proof unlike the factory bw 1356
With this set up you can pull the tranny w/out the t-case out and you also won't have to find a 4x4 tranny to put in in the first place
Another thing i'm prettyyyy shure your not going to break a dana 60 unless you plan on jumping the grand canyon.
the conversion I did was on a 1993 Not a 1994 they COULD BE DIFFERENT but i doubt it.
You would be the king of ford trucks if you made the front suspension coil over like the new superduties-just a thought, it would be very cool
by now everyone thinks i'm rambling
i'll try to figure out how to post pics
WARNING: not responsible for death injury and/or loss of pride resulting from this post
