Full manual 4 wheel conversion?

[poenix12]

hi all,new to the forum and just wanted to say hi.just wanted to say You guys got a great group here.no one on this site seems to think their a god...very pleasent since I'm a level 3 chrysler tech with 12 years in and see far too much of that every day.so cudos to all of you for treating the novice and professional alike,no-one should be shuned for trying to learn. the reason I joined was because I,m having 4x4 issues with the explorer and need a little technical info.I have the 4405 part-time t case .This truck is our winter beater so I'm not lookin to put a lot of money in it.if my diagnostics end up at the traction control system I fully plan on wiring everything up manualy with a switch panel since I have one at my disposal.now as to my questions.
1. does anyone have a wiring diagram including color codes for the 4x4/traction control system /shift motor plus pin-outs for the gem?

2.where are the relays located.I asume the front axle disconect has a vaccume/ mechanical relay also

3.does the magnetic ramp clutch in the t-case recieve a full twelve volts in full lock-up...dont want to fry it!

4.has anyone ever doen this before?if not I'll post after it's done
it should be quite simple..two switches,one to lock up the front end in the case and a dpdt to go from 4-hi/4-lo.also if the front axle disconect has issues i'll modify a choke cable to operate it as many 4 wheelers have done for years with this problem prone system for many years in all sorts of different vehicles.this I might do any way due to the fact it gets MIGHTY COLD up here in the north country and I dont want it sticking some snowy night when the misses is heading out on her 45 minuite drive to work at the hospital.

I guess thats it for now.I really do appreciate the wonderful kind people at this site and am happy to be a member.

[machinest]

Iam A new member also and had A tcase problem with my 94 sport I have a bud that works for a large ford dealer and he had it for 3 days and couldnt find the problem so I made my own shifter and got rid of the shift problems

[machinest]

I know we dont have the same tcase but I just looked at what was need to shift my tcase and made a shifter then put on warn hubs to back it up I dont need lights on my dash to tell me im in 4whl

[Sams01XplrSprt]

welcome

[poenix12]

thank you for your reply.hubs wont work for me.my front axle has an electro/vaccume operated center disconnect,unlike yours my hubs are a hub/bearing assembly like a front wheel drive car.chevy trucks started using this set-up with the s-10 and later in full size trucks with ifs .it was prone to malfunction in cold wet climates and subsequently the aftermarket came out with a mechanical conversion wich was basicaly a choke cable,a mounting bracket and hardware.once I pull things apart and investagate a little if it's possible to do i'd fill you in. also my t-case needs to have the clutch energized to engage the front drive shaft,its part of the traction control.to my understanding the gem varies voltage to alter the holding force of the t-case clutch?im thinking along the lines that it will be less fabrication to make a simple wire harness to shift between 4-low/4-hi and1 hot lead to energize the clutch.then 1 spst switch for the clutch and 1 dpdt? for 4-hi/low operation and we have just eliminated what seems to be the most problem parts of the 4x system for less than $20.00...in theory anyway.what I realy am after is the wiring diagrams for the 4x system that my ford dealer says they no longer have cause of the age.I agree I can figure it out without them but it would make life soooo much simpler.

[poenix12]

also.i think i found the shift relay to the right behind my radio face plate but not sure.if I had wire color codes I could be positive.it would make life easier if I could just work from there since my wiring harness would already be done.just bring a power source and make a switch panel to fit the dash

[machinest]

Well ford gm chri. should know how making thinks more user friendly makes them more fragil the shifter i made is the way it should be no elec.

[poenix12]

I agree,there was a time when a truck was a truck,then someone decided hey...if we make this more complicated then we can sell it for more AND charge more to repair it when it comes back.you'd be suprized how many pt cruisers come of the truck leaking oil out the head gasket with less than 5 miles on them

[BrooklynBay]

Welcome to this forum! I've moved this thread to the transmission & transfer case section so that you might get more help.