4406 Install questions

[Electrohacker]

Oh getting the awd transfer case out is easy. Shoving in the 4406 will use up your wheaties.
pssst

Don't tell anyone this, but my back is so bad I had to get a friend to come over and shove mine in. He was like" hey I just got a new Mustang want to see it?" and I was like " heck yeh bring it over right now"

yeah but if I yawn the right way my shoulder pops out... so I'll be slow and cautious

 

[Electrohacker]

I was WAAAAAY overthinking the transfercase...

I unbolted that one dumb bracket from the front (the two bolts) and it came right out.

I strapped it to the jack (BTW that piggy is ass heavy, so if anyone thinks they can get away with one strap, you can if you have two people, but I found you need two straps to keep it balanced)


Celebratory pics soon, and then the install!

 

[Electrohacker]

clean and pretty

I think that PBblaster mark is where I hit, I'll verify and mark it up soon

junk

painted up my skids with bed liner

what the neighbors get to see

 

[Electrohacker]

Shifter is fitted, might patch the rear of the hole, but the boot covers it all

give me enough straps and I'll remove my own head

test fit, plenty of room, I did already clearance the floor

further proof the 4.6 rear shaft is too long, its all I could find and I got it for $50 so I'll have it shortened

I want to check the front shaft and I'll call it a night

 

[Electrohacker]

front driveshaft was also slightly long. it was about 1/4" off

it COULD fit, but the slip joint would be maxed out, I know the front diff isnt supposed to move, but this still sounds like a really bad idea

I should test my old driveshaft as it was a double cardin.... hmmm, but I bet it's be too short

7: HEY should I have the double cardin put on the front shaft while it's in the driveline shop?

 

[Justawajz]

front driveshaft was also slightly long. it was about 1/4" off

it COULD fit, but the slip joint would be maxed out, I know the front diff isnt supposed to move, but this still sounds like a really bad idea

I should test my old driveshaft as it was a double cardin.... hmmm, but I bet it's be too short

7: HEY should I have the double cardin put on the front shaft while it's in the driveline shop?

It it be a good idea if you plan on lifting it later. If you get the superlift kit the axle drop brackets can put a bit of an angle on that front shaft and possibly cause some vibration. But if your doing a sas at some point your prob need a different shaft anyway..

 

[Electrohacker]

just took it for the first shake down run, and everything went smooth, went from 2wd to 4wd no issues, but I need to turn off the engine to get to 4wd lo... I remember reading something about that...

I have a lot of interior work to do but I threw enough of it together to take it for a spin. the new exhaust gaskets fixed whatever leak I had too!

work work work work work work work


OH and my spedometer is off, I switched the black gear for the pink one from my AWD... I guess I wasnt supposed to... oh well GPS for now

 

[Electrohacker]

just went for a longer run, at 50-55 the front driveshaft seems to vibrate badly, I may pull it tomorrow to verify, it seems to get slightly better when in 4wd hi. at 70-75 the truck handles well


oh and having the wrong speed gear has my message center reading almost 20MPG... lol that quite a good increase from 14.

 

[coonerboy]

I had a similar vibration issue from the front driveshaft. Ended up getting it shortened about 3/4" and balanced.(slip joint was completley compressed before). This took care of the vibration on mine.

 

[Electrohacker]

i just had it shortened, but i did notice that it was compressed all the way almost when i put it in... errrr there goes another $50

 

[Electrohacker]

HAAAAALP!!!!

I just switched back to the black gear for the speed sensor, and its still off...

it was reading 46 on the GPS when it was reading 50 on the speedometer

with the pink gear I THINK it was 43 GPS 50 speedometer

DOES ANYONE KNOW WHAT GEAR I SHOULD BE USING?

 

[Electrohacker]

I just found a equation that says

(current teeth * speed displayed) / actual speed

from this I get that I need a 21 tooth gear or a red gear

anyone want to confirm?

 

[Electrohacker]

YES or NO?

geo tracker shift boot with home made ring (will be painted flat black)

 

[my pos mounty]

It doesn't look bad. Can you put it under the carpet and cut the carpet up to the rubber boot with some type of small chrome "beauty ring"?
If not that isn't too bad looking. I would leave it unpainted if you leave it as is. Thats my vote

 

[Electrohacker]

that's the idea, the diamond plate is the beauty ring

 

[410Fortune]

I used a geo tracker boot too!!!

looks nice

you shouldnt have to shut the truck off to get to low range, just be stopped and in NEUTRAL not park

did you hook up the dash lights yet?

I am running the front d shaft wedged in there, the slip yoke is maxed out... no vibrations, no problems in 2 years now... I even wheeled the piss out of this 96 a few times since the bronco has been down.. the 4406 = monster 4x4 truck explorer

nice job!

I should shorten the front shaft eventually, I am sure the front pinion and U joints are not happy campers...

 

[Electrohacker]

I just sent the driveshaft out today for shortening, without the driveshaft I have no vibration so it HAS to be the problem

obviously my tracker was different from yours, lol

yes I wired the dash lights, I want to make sure Im not in 4x4 when I do tight parking lot maneuvers and 2wd to 4wd there's no major difference in the shifter... took me 5 minutes to wire up (not my first rodeo with relays)


I also ordered a 21 tooth gear hoping its right for my speedo

all the minor repairs and such that I did while doing this mod has my truck running smoother than when I bought it, I'm happy.... LETS GO WHEELIN!

 

[97sprt4x4]

i definitely like the diamond plate look, adds a little to the interior. you could paint it black so it matches everything else, but it wouldn't do it any injustice at all if you left it like that. on step closer to SAS, Congrats

Justin

 

[Electrohacker]

speedometer is still off, but not by a lot it reads 50 at 48

I need to find a 22 tooth gear.... any ideas?

 

[97sprt4x4]

It may have to do with the fact that your current set up is just not able to be dead on. if you think about it, f150s had different gears and bigger tires. You might be able to get it really close, but not dead on.

Just a thought. and if it's only two mph, it's not really worth stressing over, when you finally go SAS you'll have 33+ and you'll have to regear and change the speedo gear again anyway.

just my opinion.

Justin