4x4 Conversion Kit Chevrolet Express + GMC Savana - Key Components
***Current lead times on "Key Components" kits range from 1-3 weeks. Delivery time typically takes 7-10 days from the time of departure on most domestic shipments. International shipping is available, contact us for further details.***
This is our basic conversion kit containing the non "over-the-counter" components required to do an independent front suspension 4x4 torsion-bar conversion on a 2003-2022 G-Series 2500/3500 and 4500 van. The kit contains all the basic components that are not easy to locate, design, or build to complete the 4x4 conversion and is good for Zero to 2 inches of lift. For 4-5 inch lift kit options, visit our Hi-Lift 4x4 Conversion Kit Option.
Interested in this kit but would like to know ALL the components that go into your specific conversion? Send us a message from our contact page with your vehicle year, make, model, engine and any other details pertinent to your conversion and we'll build you a custom sheet with your vehicle specifics.
We also offer turn-key kits for 4x4 conversions if you do not want to hunt all the parts down to complete your build.
If this is your first stop on our site, take a little bit to review the vans, resources, and information on our "how do I convert my van to 4x4" page. We also have answered a lot of frequently asked questions on our FAQ page. If you have further questions, we'd be happy to answer them by phone or Email. It is our goal to make the process as seamless and productive as possible and we've gone to a great deal to design a product that is field-tested and made for a pain-resistant install.
Here are some sample pages from our GM 4x4 conversion manual. Our manuals include detailed photography, mechanical drawings, torque specs and helpful tips.
We are dedicated to making the process as straightforward and easy as possible.
Included in kit:
- Front differential mounting system and modified center link
- Bolt up transmission 4x4 conversion system (4L80, 6L90, 8L90)
- Transfer case shifter kit
GM Van to Truck Sway Bar Adapter Kit
- 4x4 GM Van Bump Stop Kit
GM Van 2" Rear Lift Kit
GM Van 4x4 Truck Hub Adapter Rings
- Subframe Cut Templates (Metal)
- Torsion bar carriage system
- Helper Kit - Threadlocker, Anti-Seize, Steel-It Weldable Stainless Steel Chassis Paint, Zip Ties, Zip Tie Tabs,
- Necessary additional "no-pain" hardware
- GM IFS Front Differential + Transfer Case Wiring Kit
- Full-Color Installation Manual with Detailed Photos, Torque Specs + Mechanical Drawings
We have done many conversions and there are variations over the years that change the requirements of our kits. Please take note of these important variations and whether they pertain to your van or not. If your vehicle option is only listed with a 9.25" option but you want to run an 8.25", contact us for ordering.
6.6 Diesel Vans - The oil pan hangs very low in 6.6 diesel vans, particularly in year models 2003-2010.5 (LMM+Prev). We only offer the 8.25" front-end kit for these model years in the 0-2" lift style. It is possible to fit a 9.25" diff in vans with LGH motor, using 9.25" differential years 2007-2010 with significant heat-sink fin trimming. This kit must be ordered over the phone.
6.6 Diesel Vans - The fuel cooler, fuel filter, or fuel lift pump often require relocating to outside the frame rail. This involves fabbing some small brackets and re-routing some fuel plumbing, we have basic support, photos for this and helpful part numbers, but no direct support is offered for this work.
6.6 Gas Vans - We only offer the 8.25" front-end kit for these model years in the 0-2" lift style. There is very limited clearance under the oil pan and oil cooler lines. 6.6 gas van conversion kits also come with motor-mount frame-brackets pre-trimmed for ease of install. If you do not want these, the manual does come with support with how to perform the cuts, but it is much easier to just replace the mounts. Return your mounts to Timberline for $100 credit.
2.8 Liter Diesel Vans - We have limited data on engine clearance under 2.8 vans and currently only offer the 8.25" front end option. All 2.8 diesel conversion kits come with pre-manufactured motor-mount frame-brackets. These are required for the conversion and vastly simplify the front-end installation.
2.8 Liter Diesel Vans - We believe that 135" wheelbase 2.8 vans require fuel system and abs system line re-routing in between the transmission and fuel tank. It's all pretty straightforward work. We supply basic part numbers and support on this, but no direct solutions or plug'n'play options.
4.3 Liter 8L90 Vans - We have only built 1 of these and used a 9.25 front differential. This required notching and welding a section of the aluminum oil pain. We believe our 8.25 front kit will work for this application without having to do the pan notch, but have not tested it.
Fitment Designed for:
Van Side - 2003-2022 Chevrolet Express 2500/3500/4500 series vans with 4L80, 6L90, and 8L90 Transmissions. Cab and chassis variants, 4500 series vans require additional fabrication to box frame for torsion bar carriage. 6.6L diesel vans require fuel filter relocation and may require fuel hoses, 135" wheelbase vans require evap box relocation.
Truck Side - Much of the design of our system is built around the 2007.5-2010 K2500/K3500 series trucks. This just happens to be the year range that most resembles the van chassis design. There are components that we've chosen outside of this year range, for instance, the transfer case, which we prefer out of the earlier 01-07 models (although newer Magna transfer cases do interface with our components).
We have a standard list of tools that we recommend listed in the front of our manual. Not every single tool is required, but having these at your disposal will facilitate your build. If you are familiar with most of these tools, you're darn capable of pulling this off.
☐ (2) Jack stands
☐ 220v welder w/ shielding gas
☐ Air compressor / pneumatic tools
☐ Angle grinder/cutter
☐ Automotive lift (2 post preferred)
☐ Combination wrenches metric and SAE
☐ Deadblow or plastic-coated hammer
☐ Deadman (Ideally 2)
☐ Drill bits/cutting oil
☐ Electric impact gun
☐ Electric or pneumatic and conventional ratchet
☐ Floor jack
☐ Hose pick
☐ Magnetic lamp
☐ Oil drain and catch
☐ Panel popper
☐ Plasma cutter (It is difficult to complete the GM conversion with only angle grinders)
☐ Pneumatic impact gun
☐ Ratcheting wrenches
☐ Socket, Torx, hex bits sets
☐ Torsion bar tensioning tool
☐ Torque wrench
☐ Transmission jack
☐ Vice grips
Additional Consumable Materials Checklist:
☐ Blue thread locker (If you prefer a different grade that’s acceptable)
☐ Brake cleaner/degreaser of your choice
☐ Brake fluid
☐ Cutting wheels, 3”/4”
☐ Electrical tape, torch/lighter, wire heat shrink, 10-16 gauge butt connectors w/ heat shrink
☐ Gasket maker (TA-29 or TA-31 Ford silicone / AC Delco Equivalent, or Black RTV)
☐ Gear oil ( calls for Full Synthetic 75W-90 ) 4-5 Quarts Front/Rear
☐ Loctite 263 thread locker, 50 mL
☐ Paint pen (included in master kits)
☐ PB blaster, WD40 or your choice of penetrating catalyst
☐ Plasma cutter consumables (if you’re using one)
☐ Shop towels
☐ Sanding disks, we use 3” roloc 30 grit, and 2” Scotch Brite discs 2" 3m Roloc sanding disk Scotch Brite
☐ Epoxy paint and a hard clear coat like a wheel coating ideal. Sub: Self-etching primer, black paint of your choice, clear-coat recommended
☐ Dex VI Transmission fluid (8L90 + 261 Transfer Cases) Typically 4 Quarts unless servicing transmission during conversion
☐ Welding wire, argon gas
(It's a lot of parts, please visit individual product listings for more information on this.)
Tips / Skill Level:
1-10 (10 being most difficult) Level 8. We like to equate the conversion to a slightly more involved job akin to a 6" 3/4 ton IFS GM lift kit, only instead of 10 hours of work, it's more like 35-45.
This product may work with other model vehicles.
Please read through this site, read through the FAQs, the product listings, and familiarize yourself with the conversion, you're going to have questions, we have answers, just let us know how we can help!
Price, Shipping, Fulfillment, Taxes, Quality and Returns
- Price + Shipping: The cost of the kit ranges from $4250-$4650 depending on your transmission. Our kits are carefully wrapped and packaged and ship LTL freight. The average cost of shipping domestically is $250 and it is recommended to have a forklift and ship to a commercial address. Shipping to residential and liftgate service adds cost. Customers in Colorado may arrange for in-person pickup within 1-2 business days of purchase taking noted lead times into consideration.
- Shipping time for full kits: We typically have a 1-week assembly requirement to package and prepare your shipment. You will be sent tracking information and signed up for email alerts unless otherwise instructed.
- Taxes: Colorado residents must pay sales tax of 7.5%, no sales tax is collected on out-of-state shipments currently.
- Quality and Returns: We are consistently complimented on the quality of our products and the ease of installation. Components are hand-built here almost exclusively in Colorado by seasoned professionals who are fanatics about design and execution. If you are in any way disappointed in the components we will issue a full refund less the cost of shipping when the product is returned. If you decide to return any components that didn't apply to your build or you changed your mind about, shipping and a 15% restocking fee will be deducted from the purchase refund.