Want to convert '97 Explorer 5.0 AWD to electronic 4x4, or manual hubs??

[AGrayson84]

Hey guys, I just registered on this forum and did some reading about swapping in a manual-shift 4x4 transfer case into these vehicles and the information seems to be very spreadout. So many different threads, and I've had to go through many pages to find a little about what I'm looking for.

My parents have a '97 5.0 with AWD, and in effort to get a little more fuel efficiency out of of the vehicle I was considering swapping in a 4x4 transfer case instead, or maybe just put manual locking hubs on the vehicle if possible. Is there any worthy gain in MPG out of swapping to a 4x4 transfer case? And if manual locking hubs are an option for this vehicle, have there been any reported worthy gains?

I have done some searching months ago and can't seem to find manual locking hubs specifically for a '97 Explorer. Can anyone confirm anything about this for me?

The next thing that puzzles me after reading several threads of AWD to 4x4 transfer case swaps is the different vehicles that you need parts from. Didn't Ford produce a model of the Explorer in '97 with the 5.0 V8 and electronic 4x4??? Because what I would like to do, if possible, is just simply swap in an electronic-shift 4x4 case, swap the driveshafts, and do whatever electrical wiring/modification necessary. My parents won't care to have a manual shift lever on the floor. So is such a swap not as easy as finding this model Explorer in a salvage yard and yanking the t-case, driveshafts, and other misc. parts???

If this specific swap has been done (with an Explorer using a VSS) can anyone point me in the direction of a thread/write-up on it? Thanks!

 

[Dan Whitaker]

Hey guys, I just registered on this forum and did some reading about swapping in a manual-shift 4x4 transfer case into these vehicles and the information seems to be very spreadout. So many different threads, and I've had to go through many pages to find a little about what I'm looking for.

My parents have a '97 5.0 with AWD, and in effort to get a little more fuel efficiency out of of the vehicle I was considering swapping in a 4x4 transfer case instead, or maybe just put manual locking hubs on the vehicle if possible. Is there any worthy gain in MPG out of swapping to a 4x4 transfer case? And if manual locking hubs are an option for this vehicle, have there been any reported worthy gains?

I have done some searching months ago and can't seem to find manual locking hubs specifically for a '97 Explorer. Can anyone confirm anything about this for me?

The next thing that puzzles me after reading several threads of AWD to 4x4 transfer case swaps is the different vehicles that you need parts from. Didn't Ford produce a model of the Explorer in '97 with the 5.0 V8 and electronic 4x4??? Because what I would like to do, if possible, is just simply swap in an electronic-shift 4x4 case, swap the driveshafts, and do whatever electrical wiring/modification necessary. My parents won't care to have a manual shift lever on the floor. So is such a swap not as easy as finding this model Explorer in a salvage yard and yanking the t-case, driveshafts, and other misc. parts???

If this specific swap has been done (with an Explorer using a VSS) can anyone point me in the direction of a thread/write-up on it? Thanks!

1. There is no way to put manual hubs on any Explorer 1995-current.
2. 5.0 Explorers were AWD or 2wd only. No seletable t-case available. A t-case froma V6 Explorer can not be used.
3. You will not see **** for mileage gains by putting a 4406 t-case in.

 

[Turdle]

I differ from Dan's Opinion

1) with a body lift a CAD front diff ( from 95-96 v6 explorer) can be fit in. This will "disconnect" the front much like unlocking a hub
2) an electric 4406 can be used, however you will need a shorter gas tank from a 2 door "sport" from the same year ( for proper vent functions)

3) combining the CAD with a 4402 for 2wd will indeed help fuel economy.

 

[snoranger]

I differ from Dan's Opinion

1) with a body lift a CAD front diff ( from 95-96 v6 explorer) can be fit in. This will "disconnect" the front much like unlocking a hub
2) an electric 4406 can be used, however you will need a shorter gas tank from a 2 door "sport" from the same year ( for proper vent functions)

3) combining the CAD with a 4402 for 2wd will indeed help fuel economy.

Just out of curiosity, why do you need a body lift for the CAD diff?

Do you have to lift the engine a little to clear the CAD unit?

 

[Turdle]

This picture from Mountaineergreens thread shows the clearance between CAD unit and oil pan, With superlift drop brackets installed. The clearance looks tight, but it might fit under the v8 without the drop????

The cad was never offered with v8 so fitting it is up to you.

Here is the thread.

http://www.explorerforum.com/forums/showthread.php?t=187449&highlight=cad

 

[BrianDye]

The V8s only came in 2WD or AWD (Sadly), but a 4406 swap seems pretty straight up; judging that you can get the necessary parts. Im in the process of looking for a beater car to drive while I do some work on my X (Including the 4406 hopefully), ive heard that the AWD robs so much power from the engine, and feels so much better in 2WD which i do not doubt. I may be wrong, but just thinking into it, it definitely seems like you would have a decent MPG increase.

 

[Dan Whitaker]

I differ from Dan's Opinion

1) with a body lift a CAD front diff ( from 95-96 v6 explorer) can be fit in. This will "disconnect" the front much like unlocking a hub
2) an electric 4406 can be used, however you will need a shorter gas tank from a 2 door "sport" from the same year ( for proper vent functions)

3) combining the CAD with a 4402 for 2wd will indeed help fuel economy.

The reason why I said you won't gain mileage was based on using the current front axle.

The easiest & chepest solution is for the OP is to sell their Explorer iand buy something else if they are looking for something that gets better mileage.