Okay so I have a 2000 ex 2wd lookin to make it a 4wd. I want to make it a BW 4406 Manual Shift. What Will I need to do the complete swap?
As Mr. Q already mentioned, you need to really think this through.
First, do you have the 5.0 in your truck? If not, you will not be able to use the BW4406 without an adapter (if there even is one).
If you do have the 5.0, and really want to do this, you will need:
a 4R70W transmission from a 4x4 (maybe just swap the tailshaft?)
the BW4406 t/case
front driveshaft from the 4.6 ford F150
the rear driveshaft from an expedition with the 5.4 without air ride
a front differential from a second gen explorer with the same gear ratio as the rear axle of your truck
the CV axles for both sides
2 wheelbearings/hubs
the left and right side 4x4 knuckles
probably ought to buy a new transmission mount now so you will have one when it is needed
4 u-joints
the lower shifter for the T/case (gonna have to buy a new one at ford)
the shifting linkage (from above to the t/case)
The shift rod and knob (been recent reports that ford discontinued the knob)
a weather seal of some type that has to be either made by, or heavily modified by you to keep water from the interior of your truck
a "beauty" boot (rubber boot in the cab)
2 1/2 quarts synthetic diff fluid
might need to/want to replace all the seals on the diff and/or the T/case
2 quarts of Mercon transmission fluid for the t/case
tube RTV
The know-how to do this (really isn't too difficult)
The tools to do it
the space to do it
the patience to do it
That list is by no means all inclusive.
AND while you have the front end apart, you may discover that the inner or outer tierods need to be replaced, or the upper/lower balljoints may also need to be replaced.
