2wd 250 to 4wd 350
 

Buying a 2005 2wd 6.0 excursion. Has the same front as the 99-04 f-250. I also Have access to an 03 f-350 4x4 6.0 automatic for a donor.
Is this a straightforward front axle swap (dana 60)?
Is this a straightforward transmission/transfer case swap?
Axle has manual lockouts, but transfer case is electronic. Will I need a bunch of electronics swapped for the transfer case or can I use the dash switch from the donor with maybe an extra safety switch to prevent accidently bumping into 4 lo?

You better be pretty good fabricator to get all the brackets and alignment correct. It's going to be a LOT of work but let us know how u make out if u get it done!

I am an excellent fabricator and alignment is my specialty, but what would I have to fabricate? If putting in a mechanical t-case, Is this not a fabrication free bolt on procedure?

Average person isn't sure what they are getting into, if you are more familiar it will be easier. I did builds before computer controls and was on firs name basis with parts guy for converting 205 cases to mount with turbo 400 trans back in the day! Looking forward to seeing pic of your results!