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410Fortune 96 AWD Ex - goes low range

Discussion in 'Offroad Projects' started by 410Fortune, September 15, 2006.

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    1. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      I picked up my transfer case last night.
      Two t cases were included in the deal, one is strictly for parts.

      The t case I will be using in my 96 5.0L AWD explorer is a 2001 F-150 BW 4406 manual shift :) this makes me very happy. I will no longer have full time AWD, instead I will have 2wd, 4hi and 4 low, increased RWHP, better MPG, and less tire wear. Also a more capable truck off road for light wheeling (getting to the fishing spot, colorado winters, etc)


      I have ALOT of research to do before I get started collecting more parts and modifying the t case so it can be installed...I am just beggining this conversion.
      Once I get a better picture of everything that is needed I can post more.

      I know I need to get the manual shifter linkage and driveshafts/driveshaft parts at the very least.

      I will have to figure out how to make a speed sensor talk to my 96 computer from this case, I will have to make this sucker fit under my truck, and I will have to modify some driveshafts to work or the T case itself before I can bolt it in.

      For now the pictures:

      Mid 80-90's full size bronco T case (possibly use the driveshaft yokes, sensors, tailhousing, etc we will see):
      [​IMG]

      The FSB t case tag:
      [​IMG]

      And now the new baby, 2001 BW 4406 manual shift:
      [​IMG]



      Oh my 4406 T case has 7 miles on it hahahaha and I bought it for likely less then Ford would pay BW for this case!! Shhhhh....dont tell anyone.

      Anyone want to buy a 96 AWD t case, work perfect, approx 85K miles.
       
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    3. '97 V8

      '97 V8 Well-Known Member

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      Sweet. You see, i have no idea why the hell BW put the sensor in there and theres no tone ring. Hey Jamie, take your sensor out and take a look, just for giggles. On this swap, there was no driveshaft modifications. Front d-shaft out of a 4.6 liter ford truck, and the rear from an expedition. The biggest problem i had with the AWD case during this swap was its reluctance to come off. You have to pull it off dead straight or it will fight you every step off the way( i know you know this Jamie). Oh consider this a subscribing for the tailshaft swap.
       
    4. Turdle

      Turdle Moderator Masterbaker Staff Member Moderator Elite Explorer

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    5. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      my new 4406 case has a sensor in the tailhousing, however I am guessing it is not gear driven and I am guessing it is not the same signal I need to simply replace my AWD VSS signal, right? hehehe

      I assume the other plug is for the dash 4x4 indicators?

      I hope I can find linkage easy, I was thinking like you 97V8 the easiest way would just to get the F-150 or expedition driveshafts and use them, modify them to fit my diff's instead of messing with taking this case apart and trying to swap yokes? I hate to open a case with 7 miles on it!
       
    6. '97 V8

      '97 V8 Well-Known Member

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      Unfortunatly it doesnt send the same signal(hell i dont know why its there). As for d-shafts, Yeah, It is way cheaper. I scored my front and rear d-shaft dirt cheap. Low miles and in very good condition. Frankly its a lot easier to bolts the case in, slide the slip yoke on the shaft and bolt far end onto 8.8 haha. Same for the front. 4 bolts and 2 straps. I like the easier way. That other plug on the front is the dash indicator thingie. I'll be hooking that up in the winter.
       
    7. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      did you have to modify the d shafts for length?
      Did they bolt up to teh front and rear yokes?
      I assume you got them from a gen III Explorer?

      Sorry I have not gone back over your thread yet and taken notes..I will but I have not had the chance and this is all very exciting :) hahaha

      Sweet if I can find the linkage & d shafts I may just drop this sucker in this weekend.

      Oh and I am familiar with removing and bench pressing the t cases, believe me!!
      right now I am saying one thing: "thank god for my bodylift!!!"
       
    8. '97 V8

      '97 V8 Well-Known Member

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      1. no, they are a straight fit. The rear slips on and is halfway through its travel. I compressed the suspension and it still had splinage left, and ilet the suspesnion droop and i still had travel. The rear is from an expedition, not an explorer. The front is from a 1997-2003 ford f-150 4.6 liter engine. It bolts right up. All you need is that front 1330 hybrid u-joint for the d-shaft to bolt up into the front yoke.


      Bodylift is god in this swap.
       
    9. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      okay one last question:

      How does your truck drive with no VSS signal currently? shifting affected?
      Assume cruise control does not work?
      any other issues?
       
    10. '97 V8

      '97 V8 Well-Known Member

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      Shifts fine, just as it did when i had a speedo. Cruise control went bye bye.

      Only issue is steering is lighter, accelarates faster and better mpg's...im pretty sure those are good issues.

      If you have any question dont hesitate to ask.
       
    11. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      find front D shaft, $100
      I believe he may also have the linkage I need :) but wills ee this afternoon


      the rear MAY be a bit more tricky, finding a Expedition in the yard......

      is your CEL on?
       
    12. '97 V8

      '97 V8 Well-Known Member

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      yes CEL is on. VSS sensor
       
    13. Turdle

      Turdle Moderator Masterbaker Staff Member Moderator Elite Explorer

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    14. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      FYI I also plan to eventually convert my front IFS to the vacuum disconnect style found on 95-01 Explorer V6 4x4's :)
       

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    15. '97 V8

      '97 V8 Well-Known Member

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      You know i always here that but what is it really?
       
    16. section525

      section525 sextion525 Elite Explorer Moderator Emeritus

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      Wasn't that only on 95-96 Explorers?
       
    17. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      POSSIBLY only one I have seen up close was a 95 truck

      so the 97+ 4x4's just always spin the CV's, diff, and front d shaft or what?

      OH wait the 97+ in 2wd is actually control trac 4x4 isnt it! I see....
      For true 2wd I would sure like to be able to disco that sucker.
       
    18. '97 V8

      '97 V8 Well-Known Member

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      yeah, they spin all the time. Im thinking that vacum disconnect is like lockouts? Not engaged, the front shaft doesnt turn, when engaged it does?
       
    19. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      it unlocks the passenger side axleshaft from the diff, so even though the cv turns it will not spin the ring and pinion of front d shaft.
      its like locking the d side hub only on your truck with the t case in 2wd, of course this is with an open diff
       
    20. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      WANTED:
      Ford F-150 97-03
      4x4 transfer case shifting linkage and shifter
      front driveshaft complete

      Ford Expedition
      front and rear driveshaft complete

      Looky looky:
      http://www.expeditionforum.com

      I have locatd a front d shaft, but I will wait until I can get all teh parts from 1 place hopefully or have located all 3


      :p
       
    21. '97 V8

      '97 V8 Well-Known Member

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      i had to buy my linkage. Damn JY's, why the hell do they throw em away.
       
    22. 410Fortune

      410Fortune ELITE BRONCO2ERER Moderator Emeritus

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      Because they think people who want an F-150 t case only want it to replace an F-150 t case
      Not smart, just leave them attached!
      So trick is to find private party, or right place right time, find Exped or truck about to hit the yard.

      Where did you buy this? Ford?
      see I havent checked your thread....argh! no time yet.....
       
      Last edited: September 16, 2006
    23. '97 V8

      '97 V8 Well-Known Member

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      ya, i had to buy my shift linkage through ford. 107 bucks for the linkage and stick. 5 bucks for the boot. YOu can make your own rod that connects the t-case to the linkage. When you go to the ford dealer ask if he can bring up a diagram and you will know exactly what im talking about.
       
    24. Stic-o

      Stic-o Elite Movie Star

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      Jamie..The VSS on a newer 150/Expo should be in the rear axle like the EX. Dosn't your current vss go to the rear axle, or is yours in the t-case? Maybe you could just rig it to your rear axle like the newer trucks?
       
    25. '97 V8

      '97 V8 Well-Known Member

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      Section525 tried that and he couldnt do it. It wouldnt read.
       
    26. Stic-o

      Stic-o Elite Movie Star

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      [QUOTE='97 V8]Section525 tried that and he couldnt do it. It wouldnt read.[/QUOTE]

      Well that's because it's Johnny :p

      so your sensor is in the case then right?
       

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