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Most common problem is the fuel cap, loose or leaking. Also possible rusted out fuel filler tube.

The part number for the metal plugs is Dorman #555-108, http://www.rockauto.com/catalog/

99-01 Explorer 5.0 Transfer case swap Has any one done a 99-01 Explorer 5.0 Transfer case swap? I found some pics of the TC's. Both 4.0 & 5.0 appear to the same TC adapter mounts (7 bolts). Just wondering if you could switch trans to TC Housing. Might have to swap output shafts?

When you use the manual shift 4406, i've read have use different drive shafts. Do you have shorten them? If so much? same length as the original?

I've got a 1991 navajo with just under 250K. I love short wheel base, you turn on a dime. Its preaty worn out though. I'd like find one in better shape to replace it. Just bought a 98 5.0 Explorer, I don't like AWD transfer case (binding when turning).

Has anyone replaced the orignal TC (Viscous Coupling) in a 5.0 Explorer with a normal electric shift TC.