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4th Gen Auto 5R55 to Manual M5OD - progress (not a How-to)

Discussion in 'Modified 2006 - 2010 Explorers' started by engineeering, July 16, 2014.

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    1. 2000StreetRod

      2000StreetRod Staff Member Moderator Elite Explorer

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      4WD control moduel?

      Are you trying to use the 2006 Explorer 4WD control module with the 2003 Ranger transfer case assembly? If so, I don't see a magnetic clutch on the 2003 wiring diagrams. I'm afraid I'm not familiar with 4WD since my Sport is only RWD. The 2000 Explorer wiring diagrams show a magnetic clutch that allows shifting from 2H to 4H at any vehicle speed and from 4H to 4L when the vehicle is stopped and the clutch pedal position switch is closed for M/T. On a 2000 it looks like the GEM outputs control the electric shift control module. I suggest spending some time to understand the wiring and functions of the various components before purchasing another transfer case.
       
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    3. 08Exploder

      08Exploder Active Member

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      Ok look into the BW 4405 that was the one I had on my 97 explorer it had the clutch pack style t case the reason is that the explorer is part tie 4wd by slight Amos through the clutch that's what auto is now 4wdhi just sends full amps to the coil to lock it in 4wd and 4 low is the only time the motor turn that's why you need to be in neutral. I woul look into seeing if that t case will work or some other t case that was offered with the manual do you have the r 1 or r2 manual ? I'm trying to do some research for you but like I said you were going to run into 4wd issues wish I was wrong though!

      Tom

      Ps looks good I'm jealous lol
       
    4. engineeering

      engineeering Active Member

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      Thanks for the tips!

      I came to the same conclusion as you after doing some review of the wiring diagrams. The 2006 is very similar to the 99-01 in terms of the transfer case. I still have to do some research ... but I believe it has similar positioning and clutch operation. The control is a bit different but the transfer cases operate the same way. I think it might give me 2hi, 4x4, and 4lo instead of awd, 4x4, and 4lo (what I had).

      Doing more research is a good suggestion... I really probably need to talk to someone who knows lots about the transfer cases before I go forward.
       
    5. 08Exploder

      08Exploder Active Member

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      Another option is to add in the manual transfer case but you would need a difrent tail housing then the one you have if you have a pic of the transmission with the tail housing please show me I'm 90% sure the bw4405 will work I actually have one laying around to check lol I rember the 5r55e extent ion housing was round on inside so the t case would slide in. I read that the splines are the same the only think that's diffeent is the connector and I gave you a pin out on the other thread of the 97 which is the same for 97-01 the difference between 97 was it had the hole for a speedo gear sensor boy was that rare to find cause 97 was the only year t case very hard to find that's why I have a 99 laying around cause someone had wrong one in my old 97. I wish you luck but this one is a pain you either have to use a ranger module or the bw4405 I'm just worried if it will bolt up to your m5od r1hd it looks like it will only way to find out is to get it and try it and then your 4wd will work just like the 06 one did

      Tom
       
    6. engineeering

      engineeering Active Member

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      I was just talking to a guy down my street that had one too! It was a pretty good deal and I passed it up cause I figured I could make it work.. dang... that rare tcase woudl have been sweet.

      decisions decisions. I will wait and think about it. I have something else to try with my ranger one still. If I can get it to operate like the ranger... I actually prefer that... 2hi, 4x4, and 4lo. Not sure if it will work though.

      ... still trying to figure out what I'm getting for operation. no action from 4x4 button. Just the 4x4lo button drops it to low gear... BUT I think it's going into 4x4 too. So I'm thinking it might be going from 2hi to 4x4lo. I do hear the shift motor run for several seconds. Longer than usual for my old ranger. I think it's moving the full distance (across 4 positions). Since the pcm is waiting for a postion signal to "stop"... the wiring of the 5 position pins is critical. ... just typing "aloud" and getting some ideas going. I may be way off....

      ...I'll sleep on it for a few days. Just HAPPY to be driving a stick in 2HI right now!!! :D

      My ranger tcase is: 2HI - 4HI - N - 4LO.
      The 06 native was: A4WD - 4HI - 4L

      "edit": The native one had a clutch... am I correct to think that the clutch engages 4wd on the fly when the vehicle senses "slip" in A4WD... and when the button is pressed for "4HI"? If so... does the t-case shift motor (in the native 06 explorer) physically move "3" positions or just "2"? This is VERY VERY important.
       
    7. 08Exploder

      08Exploder Active Member

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      You might need a new tail housing with the bw4405

      http://m.ebay.com/itm/FORD-RANGER-M5R1-4X4-TRANSMISSION-TAIL-HOUSING-89-98-/151821557923?nav=SEARCH

      The way the 06 explorer works is auto just lets the computer engage the coil in the t case when it sees slip the 4hi is just by passing the computer and constant feed to the clutch the 4lo is when the motor turns and turns all the way engaging 4lo

      The one you have now has 2lo and then motor moves to 4hi then to 4 lo if you want that 2wd sence disabling the computer all you need to do is put a relay in between the coil wire and that will give you control over the clutch disabling the computer to activate 4auto!

      Going to bed now but you look like your doing tons better than before!
      Tom
       
    8. engineeering

      engineeering Active Member

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      Thanks Tom. You're amazing.

      I'm going to bed now too. Will dive into things again after I sleep on it. Always get good ideas in my sleep :)

      Ps. I'll look into the manual option a bit more. It would be awesome if I could make this work somehow.

      Pss. Forgot to mention I have the ranger buttons and controls for 4x4 on my bench. I stripped it all including the wiring harnesses when i salvaged that truck in case of a "plan B". Lol
       
    9. engineeering

      engineeering Active Member

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      Hi Tom. I'm guessing your manual transfer case has the u joint yoke for the front axle right? I guess I would have to get a new front drive shaft.... also .. my console is already a bit cramped.... introducing another floor shifter might not be ideal. I do prefer manual. .. but I think I would have to forfeit my centre console.

      Decisions. Decisions. Lol.
       
    10. 08Exploder

      08Exploder Active Member

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      Yes the manual one uses the double u joint style compared to the round one like on the awd t cases so you would need that plus you would need a diffeent tail housing for the linkage to attach to for your transmission I don't think it will take up too much more room but yeah I can imagine crammed lol

      Tom
       
    11. engineeering

      engineeering Active Member

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      Thanks for confirming. I found 2 in the local classifieds nearby.... my buddy also has an awd 2001 explorer tcase on his shelf. Gonna grab that tmorrow or Monday (and a 2 watt 270 ohm resistor) and wire it all up (he will take it back if it doesn't work.... score). Should have my shift boot by then too!!!

      Well see how it acts once the clutch tcase is wired up. Can't wait to get her all ready for winter. Very done driving my extra temporary beater (99 honda civic). Lol
       
    12. engineeering

      engineeering Active Member

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      Ps. If it doesn't work.. I might be interested to buy your manual tcase and linkages... rather get it from someone who can confirm its functionality :) I'll keep you posted.
       
    13. 08Exploder

      08Exploder Active Member

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      Lol yeah your almost there lol can't wait for the results

      Tom
       
    14. 08Exploder

      08Exploder Active Member

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      Lol the one I have has been sitting out side for 3 years I wouldn't use it other then parts lol and I live in New Jersey you prob live 900 miles from me it wouldn't be worth it even if it was free cause tolls and gas but thanks for the support lol if you know anyone with 1987 Ford F-150 flare side bed side panels that aren't rusted they can be from 1979-1987 let me know cause I'll drive cross country for those lol

      Tom
       
    15. 08Exploder

      08Exploder Active Member

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      But the awd t case will work fine as long as it bolts up the wiring will be the same you just need to cut and splice the wiring to fit the factory connector.

      Tom
       
    16. engineeering

      engineeering Active Member

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      I'll ask my buddy. He owns one of the biggest truck salvage yards iñ the interior. Not a bad bonus i must say.

      Don't forget I'm international though. .. BC canada... but parts are easy to ship across the line. .. just not trucks.... im trying find and import a 4x4 4 door 4L ranger from Mexico. As of 2016... the 15 yr old ones (4l) are available. :) not sure how to get paperwork ready for crossing 2 borders! Lol for now I'll stick to my tcase problems. Those are problems for next year.

      ...I'll post up some pics of the installation completed to date. Some custom mounts, etc. Unfortunately my sd card died on my phone and lost most of the progress pics.... pretty bummed about that.
       
    17. engineeering

      engineeering Active Member

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      Ok. Progress update.

      Since I had to trick the pcm to think it's in neutral... I couldn't trick it to think it's in reverse (same dtr switch controls the signal of the gear). So I followed a blog on here about the "reverse light override mod". I kinda wanted to do this anyways... so I decided to do it but put 2 switches instead of 1. The second switch is wired directly to the "reverse switch" on the top of the M5OD Manual Transmission (red plug). Let there be light while in reverse gear... AND whenever I want to throw some extra light with a dash switch :)

      Here is the diagram. All I need to do is confirm which wire powers the rear lights.
      [​IMG]
       
    18. engineeering

      engineeering Active Member

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      Question about rear upper 5th door glass hatch button?

      I haven't even tapped into the wiring on the rear brake lights yet... but I noticed the rear hatch "button" that unlocks/pops open the upper glass hatch on the 5th door doesn't work ??? Does anyone know if the truck needs to be in park or something for this hatch to work? I'll check my fuses before I get too carried away....
       
    19. 08Exploder

      08Exploder Active Member

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      My guess is yes the vehicle needs to be in park for the hatch to open that would make sence since you would t want to be doing 70 and the rear glass swing open because your knee hit the button

      Tom
       
    20. 08Exploder

      08Exploder Active Member

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      You also will have a problem getting the key out of ignition of truck is not in park unless you bypassed the switch for the ignition lock!

      Tom

      Ps thanks for the shout out for that part.
       
    21. engineeering

      engineeering Active Member

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      Thanks Tom. Turns out the park switch was a second separate switch built into the stock floor shifter. I already extended that over to the ignition so there is now a "key release button" similar to other vehicles. I saw that one coming cause I took much care in inspecting that floor shifter for additional sensors wheñ dissassembling... :)
       
    22. 08Exploder

      08Exploder Active Member

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      Ok good just one comment on the drawing is the 30amp a constant battery positive or is it a switched positive off ignition switch cause if you park the truck and put it into reverse you will drain the battery cause it will turn on reverse lights make sure you find one with the ignition switch turned on when it has power? But looking good getting close to the end!

      Tom
       
    23. engineeering

      engineeering Active Member

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      Good point. Might pull power off of an unused auxiliary fuse as that is a bether solution.... might be worth running two wires so the bypass works without the ignition (direct to battery). Heck... I won't even need a relay for that... just two parallel wires. Cheaper and more functional!

      Two heads ARE better than 1. ;)
       
    24. 08Exploder

      08Exploder Active Member

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      Yup two heads are better than one sometimes it makes sence to walk away and come back to it because you end up figuring it out by taking a break plus like you said!

      Tom
       
    25. engineeering

      engineeering Active Member

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      Hi Street Rod

      Did some manual swap Advantage III editing. Your tip is exactly what I needed... Once I got started... it is quite addicting. ( in short...I ended up deleting my EGR, changing tire size, and did some other tweaks as well. LOVE THE CONTROL).

      Anyways... here's the noob question. So I'm all done with my tuning tweaks for now... and I've got an ".mtf" file (editable flash file for SCT). I want to convert to ".cef" so my x4 can upload it. Any tips? Only option on my pull-down other than save or save as (.mtf) is "export custom file for bulley dog gt"?? shouldnt there be other options to export to .cef?


      ps. for those who want to know... I'm pretty sure my truck was dying at quick stops due to my "coasting fuel shut off" was set lower than ideal for a manual (probably only okay for auto). My truck was in "coast mode" (where it shuts off injectors when coasting down hills ect to save fuel) and didn't have enough time to turn the injectors back on in time before dying when I quickly pressed the brake and clutch at a stop. I tweaked the rpm setting there and also on the idle and am eager to try it out.
       
    26. engineeering

      engineeering Active Member

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      ...after much googling.... export functionality I'm looking for is under a well hidden icon only available in the top panel entitled "program device".

      Thanks for reading though.
       

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