98 Explorer 5.0 Transfer case swap

[CDW6212R]

easier how?
It cant get much easier...

The manual install requires pulling the sets, rug, and cutting a hole for shift linkage. I gather that the electronic version just bolts in(not easily), just like the AWD case.

I don't like the thought of losing five gallons of capacity, but oh well. Regards,

 

[Turdle]

The manual install requires pulling the sets, rug, and cutting a hole for shift linkage. I gather that the electronic version just bolts in(not easily), just like the AWD case.

I don't like the thought of losing five gallons of capacity, but oh well. Regards,

Well, you still need to remove the console for the top transfer case bolts--

 

[CDW6212R]

Don't tell me that. Were you able to remove the BW4403 without pulling the interior? I keep reading where others pulled the interior to change vacuum modulators in 91-94's. I did mine from underneath on both older trucks.

 

[CougarX]

You definitely need to get the top t-case bolts from inside the truck. I don't think there is any combination of u-joints/extensions or dexterity that can get to them without removing the access panel under the console.

 

[CougarX]

But as a side note, removing the interior isn't bad at all. The seats are 4 bolts and 2 electrical connectors each and the console is 4 bolts and an electrical connector. You'll spend a lot more time trying to bench press the 4406 into place and dropping the fuel tank.

 

[CDW6212R]

H mm, so I need to leave out my console until I do the BW4406.

 

[410Fortune]

"You definitely need to get the top t-case bolts from inside the truck. I don't think there is any combination of u-joints/extensions or dexterity that can get to them without removing the access panel under the console."

unless you have a body lift

It took me all of 20 minutes to pull the seats and console, pretty easy!

Either way you choose its a simple bolt in affair with minor mods required to make it fit. The end result is *****in that is one thing we will all agree on.

 

[Turdle]

H mm, so I need to leave out my console until I do the BW4406.

Pulling the console is pretty quick really--unless it is heavily modded with wiring. I'd plan your projects for this-maybe install another multi pin plug?
Wow-I just had a good idea!!

 

[FordSMTech]

When you use the manual shift 4406, i've read have use different drive shafts. Do you have shorten them? If so much? same length as the original?

 

[410Fortune]

the bolt in with no modifications driveshafts have been posted

the front from a 97-2001 F-150 or expedition with the 4.6L will bolt in
the rear from the expedition will bolt in (I believe the air ride suspension ones will require mods)
My d shafts came from a 98 expedition, both bolt in using only a hybrid u joint at the front diff pinion

 

[Hokie]

unless you have a body lift

It took me all of 20 minutes to pull the seats and console, pretty easy!

Either way you choose its a simple bolt in affair with minor mods required to make it fit. The end result is *****in that is one thing we will all agree on.

Pulling the consoles also gives you great access for extending your tcase and tranny breathers up the firewall.

When you use the manual shift 4406, i've read have use different drive shafts. Do you have shorten them? If so much? same length as the original?

Like 410 said, the front drive shaft works with no modifications other than the hybrid U-joint. The rear will work too with no mods, just make sure the donor truck is a Triton V8 (5.4L). There are 2 different length driveshafts in Expeditions/Navigators, you want the shorter one.

 

[FordSMTech]

99-01 Explorer 5.0 Transfer case swap

Has any one done a 99-01 Explorer 5.0 Transfer case swap? I found some pics of the TC's. Both 4.0 & 5.0 appear to the same TC adapter mounts (7 bolts). Just wondering if you could switch trans to TC Housing. Might have to swap output shafts?

 

[Hokie]

Has any one done a 99-01 Explorer 5.0 Transfer case swap? I found some pics of the TC's. Both 4.0 & 5.0 appear to the same TC adapter mounts (7 bolts). Just wondering if you could switch trans to TC Housing. Might have to swap output shafts?

FlyBoyCoe put a manual 4406 in his 2000 5.0 EB Explorer. Don't believe any output shaft swapping is required. You use the output shafts of the new t-case.

 

[410Fortune]

the 4.0L t case will not fit on the back of the 5.0L 4r70w transmission, they are 6 bolt not 7 the output shafts are completely different.

 

[techieman33]

so which motor size expedition do you need to get the shafts from, 410 said a 4.6, then hokie said a 5.4?

 

[410Fortune]

they both use the same transmission but I believe Hokie did a bit more research (the 4.6L engine has the transmission a bit further forward??) then me, I just got lucky.....

If you plan to do this conversion then you should be reading the official conversion threads and taking notes, all this info is listed

 

[Turdle]

I am almost certain I ordered a 5.4l drive shaft. No air ride--

 

[Hokie]

so which motor size expedition do you need to get the shafts from, 410 said a 4.6, then hokie said a 5.4?

REAR shaft: 5.4

If you look in the swap threads, my dad and I had to research it because he got the shaft out of a 4.6 and it didn't work (5-6" too long). We even started pulling VIN's and found which letter/number in the VIN you are looking for. (we drove around town on a sunday and crawled under ever Expedition we could find on a used car lot. Ultimately we found a 4.6 and a 5.4 parked next to each other, measured and recorded the VIN. The difference in rear shaft length is very significant.

 

[gijoecam]

The transfer case is in the same place on the Expeditions with the 5.4 as the 4.6. The difference is that the 4.6 uses the 8.8 rear axle which, of course, had a shorter pinion and, therefore, a longer driveshaft than the larger 9.75 rear end. They never put the 8.8 behind the 5.4 and never put the 9.75 behind the 4.6.

The front shaft should be the same regardless of engine selection. AFAIK, they only ran one front driveshaft oon the Expeditions and F-150s of that generation.

-Joe

 

[CDW6212R]

Good details guys, that saves a lot of time for many people. Thanks,