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4406 Swap

johnmckay1969

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Joined
July 17, 2018
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Year, Model & Trim Level
1997 Mercury V8 AWD
I just bought my first Mountaineer a few weeks ago. I knew before buying it, that I wanted to do the transfer case swap.

To my surprise, I quickly located a 1997 F150 floor shift 4X4, at a u-pick it junk yard. A friend helped me pull it. We got the case, all wiring connectors, front shaft shield, linkage, shifter, and boot. The day before, I pulled a front 4.6 Expedition shaft and a rear 5.4 shaft. Unfortunately, the rear shaft was dented and bent from the crash. A local driveline shop can repair it but the cost may be more than I want to pay. I have 30 days to return it to the junk yard, if I can find a better shaft.

Here are my questions, pertaining to the front shaft.
1) Is this the correct u-joint? https://www.summitracing.com/parts/axe-1-0134 Just to confirm, this is to replace the joint at the differential end?
2) If I were fortunate enough to find a 91-94 Explorer front shaft, is it a direct bolt on or does it need some modification? I've read that this is the better option and should eliminate the possibility of vibration.

Thanks for your help!
 












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