4406 front driveshaft shortening

[Bboy]

I have a 5.0 V8 in my ranger, now I am swapping in a 4406 transfer case. I already have the case mounted and it fits in there good. When I went to put in the front driveshaft like many others It was too long. I went to the forums to find out how to cut it down and everyone just says you can but doesn't show how. I know I need to cut 3/8 - 1/2 inch off each side but while looking at the one side I noticed if I did that then it would cut into the groove for the seal. That was where I got confused and figured I would ask, if a forum already exists and I just couldn't find it that would be great but if not please leave your input here.

 

[SWIGIN]

This is why I tell people to use a 1st gen DS and a 627 flange, it'll bolt right on and be perfect.

 

[Bboy]

This is why I tell people to use a 1st gen DS and a 627 flange, it'll bolt right on and be perfect.

Like a 1st gen explorer shaft?

 

[fastpakr]

I'm confident that I used a driveshaft from a different vehicle on my '99, but now I can't remember what it actually was. If I can find it in my notes, I'll post back here.

 

[SWIGIN]

Like a 1st gen explorer shaft?

yup, even early
2nd gen had the same DS.

 

[Bboy]

yup, even early
2nd gen had the same DS.

Alright, but nobody knows how to shorten the f150 one? I know 410 has talked about it but never mentioned how.

 

[vroomzoomboom]

some of them are a real tight fit. to the point you have to have everything lined up for the to go in. ive used a stock f150 before. its a little bit of a ***** to get in, but it will go

 

[Bboy]

some of them are a real tight fit. to the point you have to have everything lined up for the to go in. ive used a stock f150 before. its a little bit of a ***** to get in, but it will go

Mine I had fully compressed and it just barely didn't make it over the lip that's on the transfer case flange. Another 1/8th inch and it probably could go on. Maybe I should just trim 2/8 inch off instead of 3/8 that way I don't interfer with the seal?

 

[fastpakr]

I had this link in my notes:

3rd Gen V8 Swaps W/ 4406 Chime In Here

Hey guys, I am just trying to collect some information. My truck has a V8 and 4R70W in it from a 96 Explorer. It also has the stock D35 TTB and Ford 8.8. My ultimate dream is to swap in a 4406 (a real transfer case as opposed to the AWD one I am going to use for now) and find driveshafts from...

www.therangerstation.com

My suspicion is that both shafts came from the F-150 that provided my transfer case. I definitely had the length on both shafts altered to fit my truck. There was also a conversion u-joint involved on the front shaft.

 

[Bboy]

This is why I tell people to use a 1st gen DS and a 627 flange, it'll bolt right on and be perfect.

I assume the 627 flange is a spicer part? Would a flange off an f150 work? I am heading to the junkyard right now so I might try to find a 1st gen shaft so trying to figure this out first

 

[Mbrooks420]

I’d have a driveline shop correctly remove the length from the tube, not the splines.

 

[fastpakr]

I’d have a driveline shop correctly remove the length from the tube, not the splines.

Thanks - I was wondering if I'd read that correctly in the initial post. Definitely don't just cut the splines.