M5ODR2+4406M

[97Sandbox]

Since I recently moved to rural Nebraska, my interest in an off-road-focused Ex has dramatically increased (I'm not getting rid of the Sport street truck project, that one's just waiting for the right 5.0 donor to come along). From what I've absorbed on here, it sounds like the 302+M5R2+4406M is a bulletproof driveline for a rig like I have in mind. I saw two 4x4 F150s in a local yard today with M5ODR2s and manual transfer cases. Would those cases be 4406s? If so, is there any difference between 4406s ran behind the 4.2/4.6/5.4? Thinking possibly they had beefier internals behind bigger engines maybe...

I went ahead and snagged the shift lever, boot, and base today because I know those aren't so easy to find. I just want to make sure I should pull the case and trans both if I go back tomorrow.

Any input is appreciated -- I'm pretty new to the 4x4 Explorer world!

 

[410Fortune]

The 4406 is really similar 94-2008
That trans and t caee combo is sought after by some of us fetching $1500+

I would do it! Want to talk about fun reliable and tough, behind the 5.0 in and explorer this is a bomb proof setup

The 4407 was also used behind some of those 5.4 trucks but they would also have the larger trans e40d/4r100
4407 is a much larger case so easy to sort out which you are looking at usually

Of course you will need a computer tune for the 5.0 to be happy with no auto behind it

 

[97Sandbox]

The 4406 is really similar 94-2008

Sounds good, I may go ahead and pull a trans and case then. I don't have a V8 Ex yet, but I don't mind sitting on parts for a while now that I have space in a barn. It can keep my 2wd M5R2 company.

The 4407 was also used behind some of those 5.4 trucks but they would also have the larger trans e40d/4r100
4407 is a much larger case so easy to sort out which you are looking at usually

I see the bigger 4407 has a PTO -- guessing that'd make it a tight squeeze under an Explorer.

Of course you will need a computer tune for the 5.0 to be happy with no auto behind it

Yep. I'll be getting an SCT to pull off the swap in my Sport -- might as well use it for a couple builds!

 

[97Sandbox]

Took 4 hours of hard work but the deed is done and I made a new friend at the salvage yard!

 

[410Fortune]

Well done!! Score city

 

[97Sandbox]

Thanks! They say the time to buy it is when you see it and this truck only had 119k on the clock. It appeared to have been hit hard on both sides of the bed to the point the frame and cab were both bent -- guessing that's why it was in the yard (and hopefully not due to drivetrain issues).

This has probably been covered before, but I'll post a brief summary of how I pulled everything using mostly hand tools in a salvage yard:

• Disconnect front and rear drive shafts with 12mm 12-point sockets. Use a prybar braced against the frame to hold the u-joints if necessary.
• Remove transmission bolts. They're 1/2" and two on the bottom point forward, the rest point back. The top two are tricky, I found it helpful to come at them through the wheel wells. There's two starter bolts too, can't remember the size but they're bigger.
• I took the transfer case off the back of the trans because the cross member it sits above holds the torsion bars and my particular donor was sitting on those torsion bars (thus I didn't want to disconnect it all and get crushed). Six 1/2" bolts hold them together and you'll need a ratcheting box wrench on the bottom two bolts or else your ratchet will get trapped as each bolt backs out.
• I then disconnected the trans cross member and pulled the case off the trans. Probably would've been easier with the cross member still in place though.
• If your yard doesn't allow you to bring jacks (like most), go grab a jack and a spare tire or two from surrounding vehicles. Stack the spares and place the jack on them for a strong, level surface. Lift the back of the trans to the floorboard and wiggle the transfer case out between the torsion bar cross member and the trans -- it really helps to have another person on the opposite side of the vehicle and work together here. Oh and don't forget to pop off the arm linking the case to the rest of the linkage on the trans.
• There was one set of wires to the case that I just cut strategically because I was in a rush (will solder later), but disconnect them from the case as you pull it free if you can.
• Now disconnect everything else linking the trans to the cab; clutch line, wire harness, shift levers. Finally you're ready to yank the trans out. I just muscled the thing out working it back/forth/up/down from the tailstock and let it drop onto a carefully placed stack of rubber floor mats. Again, having a spotter for this helps.
• Now you have the trans and case free! Don't forget to grab all the fasteners (you kept track of them right?!?). I also took the clutch and flywheel off so I could get the block plate too -- not sure if it will work on a 302, but it was free and easier than finding a '96 302/M5R2 F150 and doing all of the above again.

It should go without saying that you will want a variety of extensions -- I used many wobble extensions and had to use a u-joint to get the upper passenger side transfer case bolt. I also used long ratchets for breaking bolts free, normal ratchets to pull the bolts (and an impact wrench when I could fit it), and a stubby ratchet in a few tight spots. Flex-head ratchets help a ton too.

 

[410Fortune]

The 4406 is not an easy case to pull that crossmember situation sucks! Well done and like you said second set of hands!! I gave up once trying to get that sob over the crossmember by myself … went back the next day and there was another 4406m already pulled and on the ground so I bought that one!! Hahahaha now I wish I would have grabbed every one I have ever seen (not many, maybe 10)

 

[97Sandbox]

Hahahaha now I wish I would have grabbed every one I have ever seen (not many, maybe 10)

Interesting, I didn't realize they were that rare. I had stumbled across a couple in Wisconsin yards but I wasn't ever looking that hard because my old '97 was and current '00 is 2wd. I saw another M5R2/4406M setup in another 4.2 F150 in the yard here in Nebraska but I'm in no rush to do the job again (of course I could probably do it in half the time now that I have a strategy). It had nearly 200k on it, but then again might still be fine.