1997 Ford explorer transfer case and front drive shaft change

[James Ayers]

I have a 1997 Ford Explorer AWD 4.0 and had to change the transfer case. Got a line on an inexpensive Transfer case for a 96 Explorer. The front drive shaft has a different joint to connect to the case so I bought a front shaft for a 96 Explorer. I am having problems installing the drive shaft to the transfer case as it seems to long? I can compress the joint on the shaft but it seems like a fraction off as the u joint won't clear the "thing" on the transfer case? Any ideas?

 

[XLTrunner]

Here's a past thread that discusses the differences in drive shafts. Don't think anything was ever concluded, but might shed some light on your issue.

http://www.explorerforum.com/forums/index.php?threads/1997-explorer-awd-front-drive-shaft.318192/