4*2 to 4*4 conversion

[Ives]

Ok, I got a 99 Explorer Sport last Tuesday as an early birthday present, and I've wanted an Explorer Sport 4*4 for like 2 years now, but the problem is the one I got ins't a 4*4. Now I will say that I love my new Explorer, and this isn't some "spoiled brat syndrone", I've just been looking for an Explorer Sport 4*4 that was a decent price and decent milage for 2 years now, and my parents go me a really nice fully loaded 4*2. Because I had been saving up for so long, I now have a surplus of cash to spend on something, and I know someone is going to say college, but that's already taken care of. So now what am I to do, a dream of rootn' gone, but I still have this increadable looking, clean, fast, loaded Explorer Sport. But last night around dinner, my dad brought up the idea of getting a front axel. I began thinking, and concluded, why not, I helped a buddy of mine build a 86 F-250 from the frame up, how hard could a simple 4*2 to 4*4 conversion be. Well first of try finding NOS parts, or parts that will fit, or some kind of information telling you where to start. It isn't that easy. So has anyone hear had any expirence in a 4*2 to 4*4 conversion??? Any info would help me greatly, and I figure it couldn't be as hard as a Dana 44 swap, because I'm only intrested in putting in the standard 4*4 front that the car came with, IFS and all. I figure if I can find the parts at a junk yard it will be easier. So if any of ya'll have any suggestions, or can offer any help, it would be greatly appreciated.
Ives

 

[section525]

4WD conversions on 2nd gen Explorers are fairly easy. The entire front suspension is shared between 2 and 4 wheel drives. All you're going to need is:

The knuckles, disc brakes, etc.
half shafts
front diffy
front drive shaft
transfer case
rear 4wd drive shaft
and you'll have to get the transfer case tranny housing for your 2wd tranny.

You'll also need the 4wd computer and radio bezel with the 4wheeldrive selector knob.

Am I forgetting anything?

 

[Heath]

check the for sale section, there are a lot of guys with 2nd gens that have gone to a solid axle and they're selling their front end parts...

 

[Ives]

Ok, the mechanical aspect seems relatively easy, but the computer part, that's something else. I have a new Sony CD player in it, so I have a different radio bezel, what should I do about that, and where should I look for the standard front axle that someone took out to swap to a solid axle???
Thanks for the info.
Ives

 

[Yomie]

If you are doing this, instead of getting the computer controlled Transfer case, i would search for a Manual transfer case so you wouldn't ahve to worry about the GEM and computer.

As Section 525 said, you will need the knuckles, CV shafts, front Drive Shaft, diffy, and rear tranny housing. YOu will be able to use your stock upper and lower control arms, and t-bars

There are several people doing a Solid Front Axle swap, and have plenty of stock parts, look in the for sale boards!

Once again, i reccomend you spend the $400+ on a Manual Borg Warner 1354 Transfer Case! It will be soo much easier to install!

Search for Morrisey0 he may have a D35 front diffy, as well as JoshC, and they live somewhat close to you!

 

[Ives]

OK, so you don't suggest looking for or getting the original style of transfer case, the 4404 Modle that was in the 97 - 99. I found one at Tran-Steer, but I shouldn't get it????
Dead Link Removed
I know it's a good amount of work to put a non-stock axle in a car, 67 Mustang GT - new HiPo drag axle, and that was a pain. But hey at least I know how to weld, and have a nice welder at my house. I basically have an auto shop at my grandfather's house, where I can do anything automotive. But my only true problem is money. As I said, I do have a good amount because I was saving to but an Explorer but my dad got me one. But I don't want to spend like $3000 to put in an axle. So if you have any idea what an axle could cost and the price to put it in, I would greatly appreciate that.
Ives

 

[Heath]

For 3K you could do a solid front axle and have mad amounts of height... But going to for the stock front parts it should be much cheaper than that...

As for the transfer case, if you want an electronic one you don't want the 4404, thats from the AWD X's... I believe you want the 4405...

Someone correct me if I'm wrong please... Theres to much snow on the ground for me to go and check and make sure that mine is the 4404...

 

[Yomie]

Originally posted by Heath
As for the transfer case, if you want an electronic one you don't want the 4404, thats from the AWD X's... I believe you want the 4405...

Yes the Electronic t-case for the 4.0L is the BW4405
The maunual t-case is the BW1354

 

[Heath]

Is that the manual even in the later years???

 

[Yomie]

Ther were put in some 90-94 Explorers and rangers

But they go right in on the later explorers, namitey and buchvilleman has one

 

[Heath]

Hmmm...

 

[Ives]

I really don't want to go cutting a hole in the floor of my new X. So I don't think I need go cutting any holes into the floor board of my X. I think that the electronic route is he way to go. But I don't want to have to make a custom bezel because of my new CD player in the dash. I believe it would be possible to take a cup-holder in my console and put the selector in the cup holder. What do I need to do about the transfer case housing for my tranny. I know you can't just bolt the transfer case to the tranny, so what do I need to do short of getting a new 5 speed tranny. Also will I need to get a new computer for the X, or can I use the one that's already in it??? If I do have to get a new computer, what all do I have to do to get a new computer in it. Or, now here's where the computer guru comes out in me, can I just flash the OS and drivers to the ram that runs the onboard computer from a laptop or just swap out the RAM rather than installing a whole new computer?
Ives

 

[Yomie]

...........................Sorry

 

[section525]

You won't need to change your Explorer's computer. You'll basically need to add an addition computer (the 4wd control one).

I don't really understand your radio bezel question. Are you saying you had to make some modifications to your current one to add a new CD player? If not, the bezels are 100% interchangable. If you had to add a pocket for whatever for your new HU, you can just add it in the 4wd bezel.

As far as the rear tranny housing.. that is the only difference between the 2 and 4wd trannies. The 4 wheel drive housing can be added to your 2wd tranny (by a trained professional )

 

[Ives]

So I basically need a new tranny??? That will shoot anything out of the sky right off the bat, I don't have that kind of cash, nor will my dad allow it. But if there is somethign aftermarket that I could hood up straight off of my existing tranny, where the drive shaft connects to the tranny at the universal, then from there have the front and rear drive shafts connecting. That would be tons better, and I could then just have the linkage going into the cab, so I wouldn't need to worry about another computer. I was also talking to a buddy of mine, who's dad owns a car shop, he said that it is impossible to do this swap. The main reason is that the front end on a '99 Explorer Sport 4*2 adn 4*4 are completly different, all the way to the frame, and that the only chance I would have is to go buy another Explorer and drive it, or chop off the front of the frame and swap it. I hope it won't take that. But if there is any way of not having to do much mechanical work, I.E. - having the transmission housing re-worked. By the way, what is the difference between the housings on the 4*2 and the 4*4???? Another question. Why do I need the different housing, couldn't I theoretically just hook up the transfer case to the trany at the U-joint, and then the back drive shaft to the end of the transfer case??? Remember I'm just trying to get all the info possible here, before I go choping up my new Explorer. I want to be able to hammer out just about every aspect of this project before I go through with it, so I can get it done smoothly and quickly, with no problems. I will spend weeks getting everything laid out so I can get the job done in about a day. That's why I'm asking so many pestering questions.
Ives

 

[Heath]

You will have to get a different tranny, the T-Case needs something to bolt to, that is the tranny... You can pick one up from a bone yard, or search the net for one, they're out there to be had, you could probably even find on on this board, as well as the T-Case...

As for you buddy working at a car shop, its apparently not a FORD dealership and he's not that knowlegable with the fords... I'd trust the guys on this board before I trusted the guys at a ford dealership, a lot of these guys have taken every nut and bolt off their trucks and put them back together, if they say it can be done, then it can be done... There is proof, one guy has done it, it was a 1st gen though, and he wanted 4x4 so he gathered the parts and put them on...

 

[Ives]

Is there any way possible that I can use my tranny that I have now??? My dad will not let me put in a new tranny, his exact quote was "What have you been smoking, how high are you to ask me such a question". Yeah he is really behind me on this one. But is it possible that I could fabricate some sort of bracket that would allow the transfer case to mount to the frame??? Remember I do have a shop that I can use, where I do have access to fabrication tools. Could you give me a link to a picture of a transfer case so I can see how it needs to mount up??? With that I can devise some sort of bracket, that is flanged so that it can mount to the T-Case, and to the frame.
Thanks
Ives

 

[Heath]

I'm sure there is a divorced transfercase out there that you could use, I don't know which one though...

 

[Ives]

Couldn't I some how hook up a T-Case to a U-Joint and just link it that way if I couldn't find one that was divorced??? Remember I want to do this for as little cost as possible, because I plan on documenting everything that I do, and how I did it, so the information will be out there for other teens who wish to do the same thing. But I would also like to thank all of those who have, and are contributing information to aid me in my project, and I plan on putting all the things I had to do to get my Explorer a 4*4 on the internet so all can have.
Ives

 

[Heath]

You're going to spend more money on trial and error trying to rig something up to work than you would to do it right... So my answer would be NO, you can't... The inputs on a ford T-Case (and every married t-case that I know of, uses a shaft with splines on it... You're better off finding a transmission that came as factory equipmen in your truck but that is for a 4X4... You dad, if he's going to let you do it the other way, should be pushing you to do it this way, THE RIGHT WAY, for less cost and a better/more reliable outcome!!!