AWD to bw4406 or np205 opinions

[johnny499]

Hi guy's
I recently purchased a 98 mountaineer with a 5.0 and AWD. I want to convert it to a selectable transfer case. I am trying to decide between the bw4406 and the np205. Both have pro's and cons and I am trying to figure out which is the best choice.
The np205:
Is heavy
Only has 1.96:1 lo range
Would require custom drive shafts(I have made them before so not a problem)
Is very strong
Can be twin sticked(I always wanted to do one that way)
Has traditional yoke type drive shafts.
Easy to find.

The bw4406:
Has slip shaft output for rear drive shaft(maybe a problem once it is lifted SOA)
Not as strong
Can't be twin sticked.
Lighter
Complete bolt in option, very little fabrication.
Has 2.46:1 low range or there abouts.

This will be the first step in upgrading the mountaineer, I want to do a hp d44 SAS up front and a SOA in the rear on 33" tires and I want it to be durable. I have heard that slip shaft output housings are a problem on jeeps, but they usually have a shorter wheel base which makes for more extreme drive shaft angles and more slip joint length required. Any feed back, thoughts or experiences would be greatly appreciated.

 

[johnny499]

Well I made a decision on the transfer case. This weekend I got the drive shafts and paid for a BW4406 that I should be able to pick up Saturday. They are supposed to include the shifter assembly with it as well. I got the rear shaft from an expedition with standard suspension so it has the c/v joint instead of a single u-joint, this will be better when I do the SOA on the rear and SAS up front. I paid $210 for the three items, I need to get a conversion joint for the front shaft yet. Depending on the weather I might try putting it in this weekend.
I have read several of the conversion wright up's and it looks like the most time consuming part will be the shifter hole and boot installation.
I am excited to get this done and be rid of the AWD soccer mom crap!!

 

[vroomzoomboom]

dont forget, you will either have to modify the front furl tank bracket, or get one from a 2000 and up

 

[johnny499]

Thanks!
I did know that I would need to modify the front bracket, I hadn't read that one from a 2000+ would work. I will probably just modify this one anyway, I have lots of different tools to do so.
The whole process looks pretty straight forward and I have a backup vehicle if it takes longer than planned.

 

[johnny499]

Well Saturday was a good day. I picked up the 4406 transfer case from the junk yard in the morning. They supplied everything except the 2 bolts that mount the shifter to the extension housing. So it was a great buy at $125. From there I went to my parents house and had the mountaineer on the hoist by 1:30. I put up in the air to slide the transfer case onto the jack.

Here is the underside before deconstruction.

I cut off the 2 upper tabs on the case for clearance as suggested in other posts.

after a failed attempt to get the new transfer case in place I decided I needed to remove similar tabs from the passenger side of the case to clear the catalytic convertor.

Here I have it all back together minus the shifter assembly, skid plate and front drive shaft by 7:30.

I drained and refilled the transfer case with atf before it left the hoist.
It immediately felt better driving on the pavement and the slight hum is gone. I believe the c/v joint in the front drive shaft was going bad, I found it had a little rotational slop after I removed it.

 

[delexploder]

Man you got a great deal on your parts! I just got my mounty 4406 swap done too, its a definite improvement