4 wheel drive conversion

[slmdrngr]

hey, i was seriously considering converting my 96 exploder 4.0 from a 2 to a 4wd, what all would i need to put a front differential under it firts and be able to drive till i swap everything else? i mean everything i need to do this, just installing the front differential and such, what all do i need? any help is appreciated

 

[Lacky01]

http://www.explorerforum.com/forums//showthread.php?t=295484

make sure to do a thorough search, It's been discussed before

according to the above thread I'm in the process of this very swap. It will actually fit my needs to just go straight for an SAS. There will be a handful of guy say: "don't waste your time." It really will be much easier to try to trade your truck for a 4WD version. but I love my truck too much to do that, so I opted for the swap.

I just started flight school so I haven't been able to make any progress on it lately. in the Willamate Valley, I priced out a 1354M transfer case for $100, the front diff with CV shafts, front driveshaft, and spindles for $300. the only thing I've had trouble locating is a decently priced tranny. but thats my hurdle to get over.

I'll try to help any way I can, but I'm still learning too.

 

[slmdrngr]

thanks for the help, and yea, i cant part with mine either, would you happen to kno a list of eveything i need to install the front diff etc but not the transfer case or 4wd trans and still be able to drive, im tryin to find a list of parts, and good luck in flight school also

 

[Lacky01]

thanks man

from what I can gather:

Differential
CV shafts
Knuckles- this is important your 2WD spindles wont work, the hub and bearing assembly is held onto the knuckle via the cv shaft.
hub/bearing assemblies- buy new
rotors- might as well buy new


I *think* thats everything you need for the front suspension. make sure you do your homework, I don't wanna be responsible for any screw-ups.

 

[slmdrngr]

sweet, this is gunna be my first step on my project, going to try to start it this summer after i graduate, something ive been considering for a while, wanna do that first and get it over with, then id prolly do trans next, alo, does anybody know if i have to get the wiring harness for my 96 for the trasfer case etc.? or is it already in there tucked away?

 

[Lacky01]

If you're going for an electric shift transfer case, you'll need the GEM out of a 4x4 explorer. Swap out the GEM and add the wiring harness and control buttons I think. I'm going with a manual shift case myself. My only headache will be finding the shift linkage.

 

[slmdrngr]

oh, ok ,what exactly is a GEM? so the wiring isnt already tucked away? i thought i read somewhere that they used the same harness on the 2wd and 4wd exploders but tucked the 4wd harneses that werent in use on a 2wd

 

[Lacky01]

oh, ok ,what exactly is a GEM?

http://www.explorerforum.com/forums/showthread.php?p=1725290

http://www.explorerforum.com/forums/showthread.php?t=238263

http://www.explorerforum.com/forums//showthread.php?t=270218

the Generic Electric Module is responsible for a lot of electrical system functions, ranging from wiper speed to control-trac operation.

so the wiring isnt already tucked away? i thought i read somewhere that they used the same harness on the 2wd and 4wd exploders but tucked the 4wd harneses that werent in use on a 2wd

this I don't know. I've heard similar rumors but I've never needed to look for any harnesses that my truck doesn't need.

 

[Lacky01]

I just realized, your 90 ranger probably doesn't have a GEM. I'm not sure what the earlier trucks used.

and here's the kicker, your truck has a different setup than I thought. it has a TTB front suspension instead of the IFS setup that I was refering to. *face to the palm*

I remember a thread detailing a 4x4 swap on a TTB truck. search for it. my brain is officially tired

***HOLY EDIT BATMAN!!!***

wow. and then I re-read the first post about how your doing this on your 96 ex. disregard!! you do have the IFS, you DO have a GEM, and I really need to go to bed now.

 

[slmdrngr]

LOL, one of those days huh? i should update my vehicle, well ,i have a few, but anyways, i looked up the GEM, prolly will be my actual first step, if its possible for me to intstall it before anything else without messing anything up, but from what i can gather, it wouldnt if its the same year model, but i wasnt sure if it would make a difference since mine doesnt have 4XDIG, thanks for all the help so far, lol,this will be my first try at somethin like this, just gotta graduate, then i have the summer to go at it.....then EMT classes

 

[Lacky01]

that's the last time I try to be helpful after a long day at work

 

[slmdrngr]

lol, i kno what you mean, finally put a halfway decent pic of my ex on today, just put my new lights and grill on yesterday, and torsion twist...

 

[slmdrngr]

well, i took off my radio bezel and such, and found an extra wiring harness with a plug at the end, not sure if this would go to a 4XDIG switch or what, est i could guess, has four wires....but...i locked my keys in and no keypad, or extra keys.....

 

[Lacky01]

sorry to laugh, but HAHA! that sucks man!

it sounds like you might have provisions for the transfer case wiring. see if you can locate the GEM and if there's a harness on there for the 4x4. my guess is you will need to replace the GEM with another, but I'm not sure. the links that I posted might have that info for you.

 

[slmdrngr]

got the keys, need to get another set made, i found a gem online for like 40 bucks shipped, my year model and same engine and 4XDIG, need to order it

 

[slmdrngr]

yea, thats what i figured it was, ill have to see, i found the gem too, but from what i can tell, im just supposed to replace mine with the 4XDIG one

 

[slmdrngr]

well, i guess GEM will be first mod, the i will move to the front diff, tehn the radio bezel, then shift motor, thne find my trans and transfer case

 

[slmdrngr]

so, can i use a 4x4;trans from a ranger I guess?;ifvso, what year models will work?

did the zip tie trick yesterday, definitely worth it

 

[slmdrngr]

so, can i use a 4x4;trans from a ranger I guess?;ifvso, what year models will work?

did the zip tie trick yesterday, definitely worth it

also found my GEM

 

[slmdrngr]

alright guys, been looking into this project a little more seriously, got a pretty god job now and outta school, and just taking online classes, but i was wondering some thing before i dive into this project
1st.-Im planning on replacing the tie-rod ends, ball joints and upper and lower control arm bushing, do i replace them with 2wd, or 4wd? or will either work with front diff set up and still be ok without diff at the moment?
2nd.- will the hardware that holds my current tailshaft on my trans work to hold on the 4wd tailshaft? and will i need anything else besides that to have a 4x4 trans other than transfercase?
3rd.-which transfercase would i use? gunna do a manual locking hub set up but keep elec transfercase
4thwhen i order the rebuild kit for my trans, would i order it for 2wd, or 4x4? or are they same(4r55e)
and this is all for 1996 ford exploder 4.0 ohv