410Fortune 96 AWD Ex - goes low range

I picked up my transfer case last night.
Two t cases were included in the deal, one is strictly for parts.

The t case I will be using in my 96 5.0L AWD explorer is a 2001 F-150 BW 4406 manual shift this makes me very happy. I will no longer have full time AWD, instead I will have 2wd, 4hi and 4 low, increased RWHP, better MPG, and less tire wear. Also a more capable truck off road for light wheeling (getting to the fishing spot, colorado winters, etc)


I have ALOT of research to do before I get started collecting more parts and modifying the t case so it can be installed...I am just beggining this conversion.
Once I get a better picture of everything that is needed I can post more.

I know I need to get the manual shifter linkage and driveshafts/driveshaft parts at the very least.

I will have to figure out how to make a speed sensor talk to my 96 computer from this case, I will have to make this sucker fit under my truck, and I will have to modify some driveshafts to work or the T case itself before I can bolt it in.

For now the pictures:

Mid 80-90's full size bronco T case (possibly use the driveshaft yokes, sensors, tailhousing, etc we will see):

The FSB t case tag:

And now the new baby, 2001 BW 4406 manual shift:

Oh my 4406 T case has 7 miles on it hahahaha and I bought it for likely less then Ford would pay BW for this case!! Shhhhh....dont tell anyone.

Anyone want to buy a 96 AWD t case, work perfect, approx 85K miles.

 

[richardumberger]

2002 ranger with 5.0 and 4406

I have a 2002 ranger with 98 expo 5.0 I put a 4406 up to. if I have a 97 or 98 t case can I just get the plug for the vss and run it to the wiring harness? I noticed I had issues when I tried driving it down the road the other day and couldn't get out of second gear. I need help

 

[Turdle]

Your 98 explorer PCM and transmission should use feedback from the abs sensor on the rear differential. 97 and down pcm's used a vss on the transfer case. I think it is very difficult to cross over from one to the other.

 

[richardumberger]

can you think of a reason the truck would not be shifting like it should? tranny fluid is good. and engine and trans run before I swapped it into ranger

 

[richardumberger]

I do have 2 02 sensor codes that wouldn't cause this would it?

 

[Turdle]

I do have 2 02 sensor codes that wouldn't cause this would it?

I suggest you start a new thread in the modified 1995-2001 explorer sub forum, since that is what the issue will be related to

 

[Spudhut]

Quick question guys. I know this is an older thread; I hope someone can chime in.

I found (4) 4406 transfer cases in my local yard. I'm going to convert my 97' V8/AWD to manual shift. I have a choice between the following years:

5/96 - F150 - has right mechanical gear for my spedometer - I think the truck had over 200k miles on it.
9/98 - F150 - same electronic sensor that @410Fortune had on his
4/00 - F150

Im going to pull one this weekend so...Should I just pull the 5/96 TC since its basically a direct swap or get an 'newer' one and do conversion?

I would certainly say go with the older one since its a simpler swap...I dont want to miss out on any features on 'newer' units if they are available?

Thanks.

 

[410Fortune]

95/96 case would work perfectly!
Sorry the thread was so abandoned. I am back now

 

[Grabber12]

I don't remember the year transfer case that I ended up pulling but I did have to do the speedometer gear swap and it wasn't too difficult.if you're just trying to swap everything and go the easier route just go for the plug and play transfer case.

 

[Grabber12]

Okay so I just went back to my thread when I did this swap and I used the transfer case out of a 2000 f150 and I had to do the speedometer gear swap on the tail shaft.

 

[410Fortune]

Here she was when I sold her, what a BEAST of a truck
96, 5.0, E303 cam, 1.6 RR, TMH, Intake/2.5" single out exhaust, 4.10 L/S, 4406m 4x4, torsion twist/shackles, 3" body lift, 16" Ranger wheels, 35" tires, Charcoal interior swap

I am building a Sport trac right now......104K mile drivetrain I want to keep it so bad!!

 

[fordpickupman]

I spy 3 Explorers in this pic. lol

That rig turned out sharp. I've been looking for a set of those wheels for my bride's '98 5.0 we just picked up. I'm thinking about doing this 4406 swap at some point in the future.

 

[Grabber12]

My explore is no longer with me .I gave it to my mother inlaw. She lives in Kansas City Missouri and didn't have the proper vehicle for the weather. So I shipped it to her. miss it already, so nimble on the trails.

 

[Grabber12]

And for those who want to know it the explorer can tow..... Well I would pull my 20 foot Sea Ray 3 hours to lake Havasu with no issues.

 

[410Fortune]

Thanks for the posts
I used to tow a 20' Bayliner with my 96
Also in that pic is two explorers and a Mercury mountaineer LOL

 

[Spudhut]

Here she was when I sold her, what a BEAST of a truck
96, 5.0, E303 cam, 1.6 RR, TMH, Intake/2.5" single out exhaust, 4.10 L/S, 4406m 4x4, torsion twist/shackles, 3" body lift, 16" Ranger wheels, 35" tires, Charcoal interior swap

I am building a Sport trac right now......104K mile drivetrain I want to keep it so bad!!

Awesome looking Ex. What shackles did you pick up for it & how much twist on torsions.

 

[410Fortune]

warrior brand shackles
I raised the front high enough to clear the front tires then leveled both sides, on this 96 it turned out so well the whole truck was dang near level with 3/4 tank of fuel side to side and front to back.

More pics of the old 96

No more "wedgewood blue leather"

 

[fordpickupman]

They look “so-right” with 5-6” lift.

 

[abes.shop]

2001 F-1590 manual t case shifter bolted to trans tailhousing:

view from trans access panel interior:

new linkage rod from ford to t case:

Shift arm installed after the hole was cut using a drill and jig saw:

New 18 tooth speedo gear from ford:

Geo Tracker boot from junk yard. The way I used it I installed it from underneath the trans tunnel and through the carpet:

BAM!!! seats, center console, carpet, boot, knob all insta

 

[Bronco Guy]

Kevettom,

If I understand your question correctly, you cannot use the V6 T case behind the V8 transmission.
The bolt pattern and spline count on the output shaft are totally different. The v8 drivetrain uses a full size AOD style transmission, basically any t case that was used behind the 4r70w auto trans in the 4.6 & 5.4L trucks can be made to work, but the 4406 from the F-150 can be had with a manual shifter so you dont have to mess with wiring up a 4x4 switch and GEM module to control the 4x4 shift motor found on e t cases. Also the electric shift 4406 would require a 2 door fuel tank to make enough room for the shift motor to sit under your truck.

This manual t case in the explorer is REALLY NICE, during the recent snow storms I just reach down and pull her into 4x4 effortlessly, then back into 2wd whenever I want. Having true 4x4 in a 4 door ex makes the AWD look stupid.

I'm doing some research on the 4406 swap topic and was curious about keeping the 1354 that I have in my V6 Explorer. I currently have 2 Explorers, a 1999 SOHC V6 and a 2000 V8. I plan on keeping the V8 one, but was thinking of taking the 1354 out of the V6 Explorer to use behind the V8. Since 15 years have passed since your install, Advance Adapters now makes an adapter to put the 1354 behind the 4R70W (50-8404 : Ford late AOD to Borg Warner 1350 Adapter Kit | Advance Adapters) and you can convert the 1354 to a cable actuated shifter (Borg Warner Electric to Manual Shift Conversion Kit – Behemoth Drivetrain – Aggressive Performance). Granted the cost of these 2 items is in the $1500 range, but since I already have the 1354 case, I was considering it. I'm not sure if the adapter would allow either sets of driveshafts to work though. This keeps me from trying to source the manually shifted 4406, linkage, and driveshafts in the typical 4406 conversion. Again, since this much time has passed, I'm wondering how easy it would be to find these parts in a junkyard.

 

[fastpakr]

If you have a 1354 electrically shifted case now, you can just use a 4406 e shift case with your existing wiring. Way cheaper and more reliable than adapting to keep the 1354.