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Convert V8 AWD to BW 4406 Manual Shift- A how to thread

Discussion in 'Offroad Drivelines' started by MountaineerGreen, September 17, 2006.

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    1. Ihve4x4

      Ihve4x4 Active Member

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    3. chilsam

      chilsam New Member

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      This IS going to be a winter project for me...
       
    4. Dono

      Dono V8 Limited turbo and retired SC 4.0 OHV Elite Explorer

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      Question on the rear drive shaft guys....
      The 2000 Expedition has a different rear drive shaft, depending on air ride, or standard suspension.

      I see the standard suspension model does not seem to have the cargan joint. I guess the real question is if I need the double joint in the rear or not.-

      edit: The standard suspension shaft did not have the double cardan on it. It must be the auto suspension that has the double cardan? Strange, I'll get my hands on a auto suspension unit to have a look at it.

      Double edit: ok, self leveling suspension rear shaft doesn't have the double cardan joint either. I now have no idea what the difference is between the two shafts, other than the part number. The self leveling suspension shaft seems to be the most common, so that's what I now have.

      Triple edit: http://www.quad4x4.com/fordRdshft1999-2004.html
      It looks like the F-250 has the double cardan joint, but the shaft would need to be shortened.
       
      Last edited: December 11, 2013
    5. vroomzoomboom

      vroomzoomboom Elite Canuck STOCK SUCKS! Elite Explorer

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    6. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Air ride shaft might have a longer slip on it. :dunno:
       
    7. Dono

      Dono V8 Limited turbo and retired SC 4.0 OHV Elite Explorer

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      I'll take a picture of the one I have with air ride, and post it with measurements of each section. Then, I'll post what we had to do to make it work. That might help the next guy.
       
    8. Hybred

      Hybred New Member

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      This is what mine looked like in the end. I noticed there weren't too many pics of the finished project.
      [​IMG]

      [​IMG]
       
      Last edited: March 2, 2014
    9. 98'Exploder

      98'Exploder New Member

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      hi yall, I got a 98' Ex 5.0 with 2wd, that im converting to 4x4 and doing a SAS. im picking up a 4x4 4r70w trans and a BW 4406 with everything attached out of the same truck a wrecked 98/99 f150 w/ 110xxxMiles for $450 . i didnt read if anyone has a 3 in body lift with this transfer case if so do i have to make an Extension for the Shifter?
       
    10. Ihve4x4

      Ihve4x4 Active Member

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      I have a 2 inch lift and the only thing that I noticed was you have to cut a Bigger opening in the floor. The higher the body the longer the throw for the shifter.
       
    11. CheapThrillEX

      CheapThrillEX Active Member

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      I read this as your taking the trans and transfercase from the f150?

      The trans bell housing is not the same as the 5.0L.
       
    12. brettly86

      brettly86 New Member

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      Hey guys I'm trying to find the transfer case to do this. I need to know the ID number on the tag of the transfer case so that I can get the right transfer case everyone is using for this modification. Thanks. 2000 5.0 EB awd explorer.
       
    13. vroomzoomboom

      vroomzoomboom Elite Canuck STOCK SUCKS! Elite Explorer

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      this is the one i put in

      http://www.explorerforum.com/forums/showpost.php?p=2778386&postcount=168
       
    14. Giuseffi

      Giuseffi New Member

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      Rough estimate of how much you spent? Love the write up.. nice job
       
    15. CheapThrillEX

      CheapThrillEX Active Member

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      Rear driveshaft $80 from junkyard, went in and bought it w/o pulling it out myself. (u pull it yard didn't have any expeditions)

      Front conversion joint $15

      I bought my tcase from a "u pull it" yard during a holiday 50% off sale (local ones have them every holiday weekend), with the shifter and front driveshaft ,it was $140.

      $15 for tcase fluid

      $15 for gaskets and misc hardware.

      Then it was just my time and labor at that point.

      At the time I owned two and did them both within a couple weeks of each other for the overall same cost. I only own one of them now though, sold the other off.
       
    16. traveler

      traveler Staff Member Moderator Elite Explorer

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    17. Turdle

      Turdle I bake stuff Staff Member Moderator Elite Explorer

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    18. traveler

      traveler Staff Member Moderator Elite Explorer

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      Are there any other part numbers, from different manufacturers such as Spicer, for the conversion U-Joint required?

      I don't have an autozone nearby, and no idea where to find Conversion PDQ/Brute Force #1-0134
       
    19. kurupt

      kurupt New Member

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      I picked my conversion u joint up from Oreilly's. Went in, told them what driveshaft, to which vehicle, parts guy consulted his book, and then handed me the correct one.
       
    20. traveler

      traveler Staff Member Moderator Elite Explorer

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      do you have an O'Reillys part number?
       
    21. traveler

      traveler Staff Member Moderator Elite Explorer

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      Bigger priority: the rod connecting the Tcase to the shifter mechanism, can anyone provide me with a pic and precise measurements? Perhaps I can have one made.

      Sent from my H866C using Forum Runner
       
    22. Turdle

      Turdle I bake stuff Staff Member Moderator Elite Explorer

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      I ordered that part, but cannot find my picture with the part number.

      Still looking

      My present one is a shortened f150 linkage. [MENTION=165306]Stang5lgt[/MENTION] cut a chunk out of the middle and welded it back together. Hoping he chimes in with the application.
       
      Last edited: October 23, 2014
    23. traveler

      traveler Staff Member Moderator Elite Explorer

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      I found a link at the salvage yard. The TC was marked as coming from a 96 F150. It looks just like the one in the pic turdle provided. Its 7" long. Sound right? With that and the u-joint from O'Reillys I'm nearly ready. Gonna have new u-joints put in both driveshafts first.

      Sent from my H866C using Forum Runner
       
    24. Chad Summers

      Chad Summers Member

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      I am curious why a 1356 tcase isn't used? I ask because I have a 90 bronco sitting here rusting away with an electric shift case.

      My 96 has a double cardon ujoint on the front of the transfer case instead of a cv joint.. can I reuse my factory driveshaft on the 4406?

      Is there a slipjoint eliminator kit for the 4406 and would my factory driveshaft work with it?

      I just had a few questions I couldn't find the answers to in the reading and hoping someone can set me straight before I start collecting parts I don't need. My awd has always been annoying and after doing some more research I think the viscous coupler is most likely shot. I broke a cv joint in krogers parking lot last winter and it was pretty much full throttle to get it parked for the night until the snow let up enough to take a trailer after it. From my understanding this may have a lot to do with my 12 mpg avg as well? Either way I don't care for not being able to decide when its in 4wd and not having 4low. thanks for any help!
       
    25. ahodges

      ahodges Elite Explorer

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      There is not a way to use the factory front drive shaft from an AWD Explorer. There is an adaptor that can be purchased to use a 91-96 V6 front drive shaft with the 4406.
      Ford did not use the double carden front drive shaft with the AWD's or the 4x4 autos (1997+ for round numbers).
       
    26. chilsam

      chilsam New Member

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      What Chad said

      I have a 91 bronco that's sitting can I use the T.C and drive shafts from that ?
       

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