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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. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Yes, several members have. Aaron was maybe the first, and his thread is linked to early in this one, for details of the drive shafts needed.
       
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    3. delexploder

      delexploder Elite Explorer

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      I had the electric shift 4406 for a while, but im in a sport and the harness for the 4405 is still there from when it was a V6 , all i had to do was put the GEM from the V6 back in and its a little more work on the front gas tank mount but it worked fine
       
    4. ahodges

      ahodges Elite Explorer

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      If you are AWD and the harness isn't under the truck already (I assume it wouldn't be), the wiring should already be underneath the driver's seat, currently unused. You just need to get the extension/ pigtail from a 4x4 truck at the junk yard for the electric shift transfer case wiring. After you change out the GEM behind the radio, it is plug and play.
       
    5. Dono

      Dono V8 Limited turbo and retired SC 4.0 OHV Elite Explorer

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    6. Craigerz

      Craigerz Elite Explorer

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      Anyone know what size the 2 bolts holing the linkage on are?
       
    7. shawnwayne42

      shawnwayne42 New Member

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      Wouldnt it be easier to just use the electric controled transfer case. So all i would have to do is get the pigtail from the truck I am getting to transfer case from what other wiring would I have to get to be able to install it. Does anyone have a link to what i would have to do step by step to install an electric bw4406 into my 97 explorer 5.0 awd with the 4r70w in it?
       
    8. Craigerz

      Craigerz Elite Explorer

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    9. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      That's the first and most thorough BW4406 swap thread for the TOD version. His was a 97 also, and I don't recall if he had all of the 4WD power wires that are needed.

      Read that thread carefully, about the wiring. The short harness which plugs into the shift motor, is very easy to install, it's maybe 20" long or so. That's no trouble, the concern for my 98 and any 98-01, is if the rest of the 4WD wires are in the 302 truck wiring. I think I'll have to add a couple, which are in all of the 4WD V6 trucks with the BW4405 case. Nobody else has detailed how the wiring went with a 302 truck from 98-01. There were major changes from 97 to 98, huge changes, and it seems the 96/97's might have all of the 4WD wiring in the 302 trucks.

      I'm the one that has said the gas tank from a 91-94 might work in the 2nd gen's. I have my old 93 tank, and this Spring will try to graft the 98 fuel pump assembly into the 93 tank. If it will seal, then the tank will work. The 1st gen plastic tanks are shorter than the later steel tanks. The old 22 gallon tank is exactly the same length as the 17 gallon 95-01 Sport tank. The front tank mount bracket has to be moved back for the shift motor. The center strap mount is the same for all tanks from 1st and 2nd gen's.
       
    10. Craigerz

      Craigerz Elite Explorer

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      I am in the middle of the 4406 man swap. Had my front seats out and noticed an unused plug. Is that the one you’re talking about?

      BC67CA73-580C-478D-B1A0-F8735D779981.jpeg
       
    11. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      That looks like the one. It's behind/below the front seat, and there should be two holes in the floor. Your picture shows one hole, the other is for the 4WD harness to go through.
       
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