I looked into doing a trans swap on mine, because I hate auto transmissions as well, but here are the options and drawbacks, note: I have the 4.6L
M-5OD & transfer case from 98-02 F-150 - the problem with this swap is that it's a light duty transmission, and will generally fail epically.
If you have the 4.0L however then this is your best route as these parts can be sourced from the sport trac model.
ZF-5/ZF-6 and transfer case from a superduty (F-250 with 5.4L) - problems with this are heavy floor modification at the tunnel area is required, possible driveshaft length issues, and the shifting the ZF series transmission has been likened to "stirring a coffee can full of nuts and bolts with a long stick" and they typically have a granny first gear.
T-56 swap - Rockland standard gear can make an adapter that allows you to use a transfer case, but I can't recall the specific model. Issues - Money! T-56=money adapter=money custom driveshafts=money. Floor at tunnel has to be modified as well. Clutch issues, people doing this swap on 1500 chevys were smoking clutches left and right, regardless of which clutch, but the 1500 also weighs 2,000lbs or so more than an explorer and this may not be an issue.
I pretty much gave up on the idea of swapping my transmission, I'll just drive the truck until it craps out on me, and in the mean-time build a custom truck to take its place when it inevitably bites the big one.
Good luck though, but pretty much like any other custom work it comes down to time and money.
