4406 swap questions

[Josh C.]

So I read through a lot of the threads on the 4406 swap last night...so much reading I was dreaming about the conversion. Even with everything I read I would like to clear up a few things.

I'm in the market for another explorer. I have a 2wd v6 right now and I want to move to a 4x4. The v6 offers a true 4x4 but all my reading led me to believe that a v8 with the TC swap was the greatest thing since sliced bread.

I want to make sure I understand the VSS differences, so please correct me if I misunderstand anything. I plan on a manual swap and want to keep this as simple as possible:

Explorers from 1999 to 2001 will not need to do any sort of modification to the VSS because the Explorer VSS is not located in the Tcase?
If I purchase an Explorer from these years I can use ANY Tcase from the F150 year range of 97-2003 i would just have to plug the VSS hole on the donor Tcase?

Explorers from 1996-1998 have the VSS located in the Tcase?
If I purchase an Explorer from these years I should look for a donor Tcase from 97-99 F150's because these F150 years have the VSS drive gear all ready installed? A different color VSS gear (gear with different teeth) on the explorer side may have to be switched out so the speedo reflects the correct speed?
If I purchase a Donor Tcase from a 2000-2003 F150 I will have to install a drive gear into the Tcase like 410Fortune did?

Thanks for helping my Brontosaurus brain digest this.

 

[R1dd1cK]

Sounds like you hit this one one the head almost I have a 98 v8 awd and the vss is in the rear diff. Other then that all the info you have is right.

 

[Josh C.]

K thanks. You also answered my question of where the VSS is located in the later model G2 Explorers.

 

[R1dd1cK]

Glad to help.

 

[Josh C.]

More questions

I just received my manual BW4406 Tcase and after looking at it I have a few question.

1. On the back of the case there is a brown wire, where does it go/what does it do - I found this answer, its for a later model f150 magic clutch thingy, not need for 4406 swap

2. On the front of the case there is a hose nipple, what attaches to it/what does it do? My 4404 has a nipple on it also but no hose attached

3. Also on the front of the case below the nipple is a threaded hole for some type of sensor. My 4404 doesn't have anything like that. Do I need a sensor there? Obviously I need to plug it with something. I think this link #18 covers what the hole is for, am I correct? I dont have the sensor does anyone know what size it is or part number? http://www.explorerforum.com/forums/showthread.php?t=166726&highlight=4406+rubber

Thanks

 

[vroomzoomboom]

that sensor should be for your 4x4 indicator light in the dash. i found a old ford number 4L3Z-7E440-AB. call a parts store, they might be able to cross ref it. you will also need the pig tail end as well.
as for the hose nipple, that is just a breather tube for the case. if you can find a vacuum tube that fits on it, that will work. you can mount it up on top of the trans or some place higher.

 

[BackBone]

that sensor should be for your 4x4 indicator light in the dash. i found a old ford number 4L3Z-7E440-AB. call a parts store, they might be able to cross ref it. you will also need the pig tail end as well.
as for the hose nipple, that is just a breather tube for the case. if you can find a vacuum tube that fits on it, that will work. you can mount it up on top of the trans or some place higher.

Great post! This really helps me because I just did the conversion and that switch actually broke on my x-case.

Here is a helpful link on a f-150 forum regarding the switch ( or "oil switch" as it is called in the post )

http://www.f150online.com/forums/other-powertrain/257496-need-help-4x4-2.html