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96 5.0l RWD to hi-lo 4x4
- Thread starter Mangus17
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- Joined
- August 3, 2000
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- NORTH IDAHO, 7B
- Year, Model & Trim Level
- B2 "Slightly" Modified
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- FOURTEN
yes the dash switch from any 95-01 explorer or 98-11 ranger will work
the last part about the nss wire;
so the v8 explorer never had 4x4 of any kind
so Ford never installed the neutral safety wire that feeds the gem module or 4x4 controller module. so the v8 explorer is missing a wire that normally goes from the dtrs (transmission digital range sensor, aka neutral safety switch for you chevy guys) up to the 42 pin connector (c115 in explorer)
you will need to add this wire or tap into the neutral safety circuit in order to get the 4x4 control module to work
the 4x4 will not shift into 4 low without first knowing you are stopped and in neutral.... this is the wire that confirms you are in N
red white wire from this diagram; circuit 463, nss in to gem (or in our case motorolla box)
the last part about the nss wire;
so the v8 explorer never had 4x4 of any kind
so Ford never installed the neutral safety wire that feeds the gem module or 4x4 controller module. so the v8 explorer is missing a wire that normally goes from the dtrs (transmission digital range sensor, aka neutral safety switch for you chevy guys) up to the 42 pin connector (c115 in explorer)
you will need to add this wire or tap into the neutral safety circuit in order to get the 4x4 control module to work
the 4x4 will not shift into 4 low without first knowing you are stopped and in neutral.... this is the wire that confirms you are in N
red white wire from this diagram; circuit 463, nss in to gem (or in our case motorolla box)
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- Joined
- August 3, 2000
- Messages
- 32,737
- Reaction score
- 9,519
- City, State
- NORTH IDAHO, 7B
- Year, Model & Trim Level
- B2 "Slightly" Modified
- Callsign
- FOURTEN
for your info, manual t case into v8 truck;
a blast from the past!!
a blast from the past!!
- Joined
- August 3, 2000
- Messages
- 32,737
- Reaction score
- 9,519
- City, State
- NORTH IDAHO, 7B
- Year, Model & Trim Level
- B2 "Slightly" Modified
- Callsign
- FOURTEN
its not even close to your leg believe it or not
We have 2 explorers setup this way around here and a ranger with more on the way
We have 2 explorers setup this way around here and a ranger with more on the way
- Joined
- August 3, 2000
- Messages
- 32,737
- Reaction score
- 9,519
- City, State
- NORTH IDAHO, 7B
- Year, Model & Trim Level
- B2 "Slightly" Modified
- Callsign
- FOURTEN
same driveshafts
4406 is a 4406 whether it is manual shift or e shift
The 4406 can actually come from any f150 with a 4.6 or the 4.2L v6 all the way up to 2014
ther 97-98 trucks are the only ones with the speed sensor in the tailhousing, which you do not need.
4406 is a 4406 whether it is manual shift or e shift
The 4406 can actually come from any f150 with a 4.6 or the 4.2L v6 all the way up to 2014
ther 97-98 trucks are the only ones with the speed sensor in the tailhousing, which you do not need.
- Joined
- August 3, 2000
- Messages
- 32,737
- Reaction score
- 9,519
- City, State
- NORTH IDAHO, 7B
- Year, Model & Trim Level
- B2 "Slightly" Modified
- Callsign
- FOURTEN
its called the transfer case shifter
It mounts to the tail housing of the transmission
There is a knob, a shift lever, shift mechanism and the connecting rod to the t case
Here is my very old thread (2006) when I converted my old 96 Explorer from AWD to 4x4:
410Fortune 96 AWD Ex - goes low range
It mounts to the tail housing of the transmission
There is a knob, a shift lever, shift mechanism and the connecting rod to the t case
Here is my very old thread (2006) when I converted my old 96 Explorer from AWD to 4x4:
410Fortune 96 AWD Ex - goes low range
- Joined
- August 3, 2000
- Messages
- 32,737
- Reaction score
- 9,519
- City, State
- NORTH IDAHO, 7B
- Year, Model & Trim Level
- B2 "Slightly" Modified
- Callsign
- FOURTEN
yes
Sometimes you have to shorten the front driveshaft, in my old 96 the front d shaft was so tight I had to use a pry bar to install it, but it fit. Years later I would learn that with a grinder I could remove 1" from the slip yoke on both sides of the front shaft (male and female) and gain 1/2" to make it fit easier.
For the rear driveshaft, since 97-98 expeditions are getting harder to find and the junk yards basically dent every single F150 rear driveshaft with their forklifts, I usually just buy a dented f150 shaft at discount (due to the dent) and have it re tubed at local driveline shop to fit my project.
You will need a conversion U joint at the front shaft where it meets the front diff
You MIGHT need a conversion U joint on the the rear d shaft as well depending on which driveshaft you get.
The only other thing that needs modification, does not just "bolt up" is the 4x4 high and the 4x4 low lights in the dash. I run two wires from the new t case up through the floor to the GEM module. At the GEM module I cut the 4x4 and 4low wires where they go to the dash lights and hook them up directly to the new T case
There are some other tricks to know, like shave all the aluminum ears off the 4406 t case that are not needed, it makes it fit better. Also I modify the transmission cross member to move the 4406 over to the passenger side about 3/8", this helps with the fit, moves the rear d shaft away from the fuel tank shield and also gets rid of rear vibrations some rigs experience from 60-75 mph
There you go 20+ years of conversion experience wrapped up into one thread. The school of hard knocks is a good teacher
Sometimes you have to shorten the front driveshaft, in my old 96 the front d shaft was so tight I had to use a pry bar to install it, but it fit. Years later I would learn that with a grinder I could remove 1" from the slip yoke on both sides of the front shaft (male and female) and gain 1/2" to make it fit easier.
For the rear driveshaft, since 97-98 expeditions are getting harder to find and the junk yards basically dent every single F150 rear driveshaft with their forklifts, I usually just buy a dented f150 shaft at discount (due to the dent) and have it re tubed at local driveline shop to fit my project.
You will need a conversion U joint at the front shaft where it meets the front diff
You MIGHT need a conversion U joint on the the rear d shaft as well depending on which driveshaft you get.
The only other thing that needs modification, does not just "bolt up" is the 4x4 high and the 4x4 low lights in the dash. I run two wires from the new t case up through the floor to the GEM module. At the GEM module I cut the 4x4 and 4low wires where they go to the dash lights and hook them up directly to the new T case
There are some other tricks to know, like shave all the aluminum ears off the 4406 t case that are not needed, it makes it fit better. Also I modify the transmission cross member to move the 4406 over to the passenger side about 3/8", this helps with the fit, moves the rear d shaft away from the fuel tank shield and also gets rid of rear vibrations some rigs experience from 60-75 mph
There you go 20+ years of conversion experience wrapped up into one thread. The school of hard knocks is a good teacher
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