97 Xlimited 4406e problem

[97xlimited]

Its been a couple days since posting so I figured I would. I hope to run this post until a conclusive end since a lot of post do not finish out.
I went to the salvage yard last Saturday and found that the Expy and f150 are set up the same as the 4406 in the explorer. In some cases the angles are more extreme or less but not by much.(a deg or two)
Not all Expys have a double cardan rear. It seems not to be installed until late 97-up. It seems to have been used due to a increase in pinion angle, but given these vehicles all are sitting on cement blocks at a varying 45deg angle the measurements are probably not completely accurate. It was fun trying to subtract the slope out of the measurement.
The 95-96 explorers also ran a cardan in the front shaft before switching to the pancake CV in 97, but the shaft has the large bolt pattern(3x3x4) on the t-case flange. The 4406e in my truck uses the small bolt pattern(2.5x2.5x3.5) I did not check the bolt pattern of other 4406 out there, but im assuming they are the same. Entrixables 627 yoke adds the small bolt pattern to a gen 1 shaft. The only real difference between them is the gen 1 uses 1310 series joints and the gen 2 shaft (95-96 only) uses heavier 1350 joints(I think).
I'm going to see if a 4405 t-case, front shaft and rear shaft (out of a 96) will be a direct swap to my current setup. The 4406 does introduce a compound angle due to the increased offset of the front driveshaft, if to extreme and coupled with the 7deg working angle at the t-case the front shaft may need dual double cardans ($450) to run completely smooth. I do not have the original 4404 to measure here so I will have to find out today if possible. Every 1/2 inch = 1 deg of offset to the differential front or rear.
A 4405 would be original demensions and angles, but come with its own issues. Does anyone know the HP rating for one? I think they used the 4405 behind the V8's in 96, but can't verify.

 

[97xlimited]

Went out to the yard again on Monday to check out the 4405 and other stuff
The 4405 looks like it would swap but it runs a different clutch type, which could be problematic, as well as the shift fork. The gems in the truck are for use with the 4405 so the software should work ok, could be my issue now with the 4406e.
I think I may hold off on drive-shafts, but did find out from Tom Woods that if the drive-shaft does not fix the issue I could return it for a full refund MINUS the shipping back to them and the $10 dollar packaging fee.
The first driveshaft in this truck was shortened wrong (cut in the middle of the tube and rewelded out of phase). Then the slip yoke was forced together in phase shearing off one of the splines. It did not "slip" well. I don't know how long they ran it like that, but it could have ruined the t-case.
I put the shaft back in the truck and have been driving around more. The vibration is present whether the shaft has torque or not so it seems (Brown wire Mod). It is just more noticeable with torque. To some degree it almost just seems to growl more (bad t-case bearing?) I have pulled this shaft and put it back in four times now and everytime the symptoms change to a degree.
I really think im going to take the t-case apart and check it, or just swap it with another. Unfortunately its getting cold here so it may have to wait. I would like to hear bout the 4405 in one of these trucks I can get one with 90k($100 w/d-shafts) or another 4406 with 90k($250). I have to pull this one and check it first, but if the 4405 will hold up to the torque then maybe.

 

[97xlimited]

Solved

Im posting and update for my explorer which actually was sold a week ago. After fixing the vibration issues I was approached by someone who offered me a deal I couldn't refuse.
I decided to open up the 4406 and found the front output bearing had excessive play. Most likely due to the bad front shaft that was in the truck when I bought it. I replaced the bearings on the front output shaft which did not get rid of all of it, but it improved 90%. The driveshaft from the driveline shop fixed the remaining issues. Im sure the gen 1 shaft with the conversion yoke would have done the same thing.
Thanks to everyone who offered their time and effort on this I appreciate it. I hope this information may help others. Im currently looking for a good 95-96 model explorer so I sure I will be back.

 

[Dono]

Awesome....
So, the message for the rest of us getting ready to do the swap is to:
1. rebuild the 4406 before installing it (They are all used, with probably quite a few miles on them).
2. Use the 1st gen front shaft with the adapters to avoid vibration.

Your hard work is appreciated. Hope to see you back.