4x2 to 4x4 conversion on 2002

[Hitchhikingmike]

Yes you read that right, I am interested in converting my 2x4 '02 explorer to a 4x4 vehicle. Yes I certainly understand how such an over whelming project this would be and how economically its is not logical compared to just trading it in for a 4x4 explorer. However I would just like to at least entertaining the idea of doing so, as I may do this one day soon.

My explorer is a 2002, 4.0L, automatic XLS.

One of my questions is what parts would I need to take part in this conversion? Is my list correct of parts needed?

• transfer case
• front left and right drive shaft
• front differential with maching gearing to back differential
• front drive shaft
• shorter rear drive shaft to accomodate t-case
• front wheel locking hubs
• shorter transmission output shaft to accomodate t-case
• transmission rear housing to bolt on t-case
• 4x4 dash switch
• skid plates

I have a few more questions, I have no idea how the electronics of the transfer case would be controlled. Would I also have to purchase another computer to control the transfer case with the dash switch? Or can i just wire it into my existing computer?

I have no idea how the electrical motor on the transfer case would be controlled, the dash switch doesn't hook directly up to the t-case does it?

I know that in 4x4 mode the abs brakes would also have to be disabled, is this disabling system part of the transfer case electrical system?

Can the explorer's current computer already be used to just plug in the transfer case and dash switch to start using the 4x4 system?

Thanks

 

[gijoecam]

Mechanically, it's not impossible. Electrically, it'd be a nightmare. To insatll the OEM control system, you'd essentially need a donor wiring harness and all the associated parts out of a same-year 4x4. Otherwise you'll have a wiring nightmare on your hands... it's SO not worth it... sell it and buy a 4x4. Really...

 

[Hitchhikingmike]

What if I could find a manual transfer case? I have never seen a manual transfer case on any other 3rd gen explorer before though.

Does anyone know if any manual transfer cases from any f-150, rangers or previous generation explorers would bolt right up to a 3rd gen explorer 5R55W?

I still haven't ruled out the electronic transfer case. Perhaps I should start calling some ford dealerships and ask if they know where the 4x4 computer is located. I know on the 2nd gen explorers it was located in the trunk under the side window.

 

[AMMO_HOOAH]

I think you and this guy need to get together and swap parts lol, or whole vehicles.