98 Explorer 5.0 Transfer case swap

[Hokie]

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

We're here to help

I know it was annoying for dad (VA MTNR) and I as he had the wrong shaft and had to source one quickly so I could drive the truck back to IN from VA.

 

[SSmokin Joe]

Whats up. Nice site you got here. I'm a nube to this but I was reading here and is it correct that you can switch to a manual transfer case in a 98 Explorer. Mine is a V6 and was considering a tcase switch to help with fuel mileage. Would it be worth it ?
Thanks in advance

 

[palavine1951]

On a 2002 Ex Sport there is a welded in cross member that will have to be removed because the 4406 is so big. I had to cut the cross member out and with the help of my fabricating friends we built a cross member below the tc. The clearances are factions of an inch. I'm still trying to get the Electronic shift motor to work. (1354 on the right and 4406 on the left)(bottom pic show where I cut the cross member)

 

[410Fortune]

to get the shift motor to work you will likely need to add one wire to your 5.0 transmission harness.
All 5.0 are either rwd or AWD, they never had electronic shift 4x4. So there is one neutral safety wire that is missing from the harness. The trucks gem module wants to see an input from this wire before it will shift the t case motor.