410Fortune 96 AWD Ex - goes low range

I picked up my transfer case last night.
Two t cases were included in the deal, one is strictly for parts.

The t case I will be using in my 96 5.0L AWD explorer is a 2001 F-150 BW 4406 manual shift this makes me very happy. I will no longer have full time AWD, instead I will have 2wd, 4hi and 4 low, increased RWHP, better MPG, and less tire wear. Also a more capable truck off road for light wheeling (getting to the fishing spot, colorado winters, etc)


I have ALOT of research to do before I get started collecting more parts and modifying the t case so it can be installed...I am just beggining this conversion.
Once I get a better picture of everything that is needed I can post more.

I know I need to get the manual shifter linkage and driveshafts/driveshaft parts at the very least.

I will have to figure out how to make a speed sensor talk to my 96 computer from this case, I will have to make this sucker fit under my truck, and I will have to modify some driveshafts to work or the T case itself before I can bolt it in.

For now the pictures:

Mid 80-90's full size bronco T case (possibly use the driveshaft yokes, sensors, tailhousing, etc we will see):

The FSB t case tag:

And now the new baby, 2001 BW 4406 manual shift:

Oh my 4406 T case has 7 miles on it hahahaha and I bought it for likely less then Ford would pay BW for this case!! Shhhhh....dont tell anyone.

Anyone want to buy a 96 AWD t case, work perfect, approx 85K miles.

 

['97 V8]

Bottom line, will not doing this affect in any way the trandfer cases use.

 

[410Fortune]

you know that grindage you are running into?
well..........


You should be able to put the case in LOW range while stopped in either P or N with NO GRINDING

that brings up another topic. Can you go from 2wd to 4hi while driving with a manual case?? hehehehe I assume you can under 45 mph but I have not tried it yet.

 

[V8BoatBuilder]

I'm not sure why you'd want a N safet switch for low, I can't even shift into low if I put in N. I have to be completly in P and no tension on the t/c. I tried in N, but the tranny still turns the guts of the t/c and I get grindage! So P is my only option.

Odd... My electric shift works fine in N, and the guts of the case (except the clutch) should be the same. I can also enter 4hi at high speed.

Jamie, I'd place money on that extra wire being for the NSS, I don't think the manual cases would have a clutch.

On another note, many ranger owners drop their vacuum hubs for explorer drive flanges. One could theoretically "trade" with a Ranger, but there are some good reasons that the Ranger guys drop the hubs.

 

[MountaineerGreen]

you know that grindage you are running into?
well..........


You should be able to put the case in LOW range while stopped in either P or N with NO GRINDING

that brings up another topic. Can you go from 2wd to 4hi while driving with a manual case?? hehehehe I assume you can under 45 mph but I have not tried it yet.

When I try to put my case into 4low sitting still in neutral, there is a grinding sound that can be felt through the stick. If you shut the engine off, you can pull it right into gear. I can usually shift it into 4low when in park no problem. I have no idea why.

The F150 owners manual says the case can be put into four high at speeds of up to 55 miles per hour I believe.

 

[FROADER]

The F150 owners manual says the case can be put into four high at speeds of up to 55 miles per hour I believe.

So which one of you guys is going to try it out and report back with the result? :

 

[MountaineerGreen]

So which one of you guys is going to try it out and report back with the result? :

Ive put mine into 4hi at about 45 with no problems.

 

[FROADER]

Oh...that's not as exciting as I hoped it would be.

Well that's good.

 

[MountaineerGreen]

Oh...that's not as exciting as I hoped it would be.

I would say sorry to disappoint, but I'm not sorry

 

[FROADER]

Haha, I definitely don't wish harm on anyones' truck, but ya know what I mean...

 

['97 V8]

putting the truck back into 2wd grids in nuetral i think.

 

[boominXplorer]

Yeah I grind going either way from N unless I go kinda swiftly, then she wont

 

[410Fortune]

I did th eswitch into 4hi the other day at about 40 MPH, worked fine.

Now to figure out the brown wire........

 

[AMMO_HOOAH]

Glad to see everything's going smooth, and to see I'm not the only one that can't shift in N. I don't mind anyway, if you can't put it into P to shift then you probably have more problems than 4lo will help!

 

['97 V8]

Can anyone here do me a favor and get me a ford part number for the tone ring inside the t-case?

 

[410Fortune]

Call the speedometer guys I posted earlier in this thread, they have them
its a 9 tooth brown

 

['97 V8]

Call the speedometer guys I posted earlier in this thread, they have them
its a 9 tooth brown

they dont have a 9 tooth brown...they have an 8 tooth. Does that sound right? The diamater is 1 3/8

 

[410Fortune]

I wish I knew, it should be correct
When I thought I counted the teeth while it was apart I would later learn my method for counting was wrong.

Ford dealer cannot give you a part number?
What about Borg Warner?

My logic tells me I seriously doubt they made two browns.

 

[AMMO_HOOAH]

WOW, still no luck on the speedo stuff that sucks. I'm really glad I lucked out with mine bolting right in, and working. Best of luck man.

 

[410Fortune]

I would order the gear from the speedo place, if its 8 tooth instead of 9 you can just use a different tooth speedo gear to make up the difference.

then drop the tank and d shaft a bit, remove the tailhousing, install your new gear, and go!
I cant wait to find out if your gear is in there and fell apart or what!
its crazy!

 

['97 V8]

I would order the gear from the speedo place, if its 8 tooth instead of 9 you can just use a different tooth speedo gear to make up the difference.

then drop the tank and d shaft a bit, remove the tailhousing, install your new gear, and go!
I cant wait to find out if your gear is in there and fell apart or what!
its crazy!

haha yeah, i would laugh so hard if it did fall out.