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Jim:
As Ken mentioned, this is a major job you are looking at, I'm not sure if it can be done or not, but here are some ideas/thoughts:
1: Most Hybrids are configured with a "pancake" motor between the engine and trans, the clearances associated with this motor are incredibly tight to optimize efficiency. This motor is used for the following functions:
a. To provide drive torque.
b. To recharge the batteries.
c. To start the gas engine.
d. Assist in braking (this is when the majority of battery recharging is done).
2: Hybrid vehicles are designed from the ground up to ensure light weight in order to compensate for the mass of the battery bank and improve efficiency. You are talking about starting with a base vehicle that weighs 4300 pounds, at least 1000 pounds more than a complete Hybrid car!
3: It takes an incredible amount of electronics and software to run such a vehilce, this warning is above and beyond the mechanical issues. I have been in the automotive electronics industry for the last 10 years and I wouldn't consider tackling this without an entire team of experts.
4: My best piece of advice, if you really want to go forward with this, would be to find a totalled Ford Hybrid SUV. From there, take the entire drivetrain, and electronics and transfer all the pieces into the gutted 245. Please note that the Ford Hybrid SUV is what I call a "power Hybrid", not an "efficiency Hybrid" like a Toyota Prius.
Finally, if efficiency isn't of great concern to you, consider doing a Ford 302 V8 swap... all the parts and even a kit is available... easy 300HP with some tweaking.
Good luck!
jorrell
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