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Join Date: Aug 2007
Location: Manor, TX
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There are some differences in both the engine and trans but it's mostly a bolt up situation. The 99 engine will be efuel vs a mechanical pump on the 96. The injectors are larger split shot and need different programming unless the 96 is a California truck. The block is the same and will bolt right up. Accessories are different so you will need to swap the mounts or convert the brakes on the 96 to hydroboost so you can ditch the vacuum pump. The intake plenum is smaller on the 96 so you will either need to make the sypder and intercooler from the 99 work or swap to the smaller plenums so you can use the non intercooled 96 setup.
If you have a auto in both trucks, they are basically the same with the 99 having some extra sensors and a pwm solenoid for the torque converter vs a on/off one. The 96 transfer case will bolt up to the 99 trans which will allow you to keep your drive shafts but the 99 transfer case is stronger.
If it were me I would make a hybrid using as many parts from the 99 as I could. I would swap to the 99 pcm which will control the fuel pump and make the transmission swap easier. I would also use the 99 rear axle for disk brakes and create a hybrid front axle. The 99 should have a solid dana 50 front axle with better disk brakes than the 96 dana 60. I would swap the knuckles which are a direct bolt on and the stub shafts which would give you a dana 60 that's a direct bolt up to the 96 with better brakes. The down side is the unitbearing from the 99 but you would have matching lug patterns and 4 wheel disk brakes. I would probably also transfer over all the 99 abs system.
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