98 Explorer 5.0 Transfer case swap

[FordSMTech]

Has anyone replaced the orignal TC (Viscous Coupling) in a 5.0 Explorer with a normal electric shift TC.

 

[Hokie]

Has anyone replaced the orignal TC (Viscous Coupling) in a 5.0 Explorer with a normal electric shift TC.

Yes we have. Its an amazing mod worth every single penny!

Search for "4406" (The model of B/W t-case you will need) and you will see that you have two options. A manual (which I have and LOVE) and an electric. Both are out of an F-150/Expedition/Navigator so you gain tremendous strength over the stock AWD unit.

I personally used my 4LOW many, many times this past weekend on a wheelin' trip around Ouray, CO

 

[BrooklynBay]

Welcome to this forum!

 

[Turdle]

Both the electric and the manual 4406 can be swapped in-remember though, the electric case, having a shift motor on the rear--needs a "2 door sport" gas tank for clearance--

 

[gijoecam]

Both the electric and the manual 4406 can be swapped in-remember though, the electric case, having a shift motor on the rear--needs a "2 door sport" gas tank for clearance--

Doesn't it also need an elaborate electronic mechanism for making it shift? (For the electric case the original poster asked about) None of the electric-shift cases will be a plug-and-play affair.

-Joe

 

[410Fortune]

yes your truck needs ALOT of work done in order to convert to the e shift 4406 t case (psssssst go manual)

 

[Hokie]

yes your truck needs ALOT of work done in order to convert to the e shift 4406 t case (psssssst go manual)

I agree with 410. I wanted to go electronic b/c I didn't like the idea of cutting a hole in the floor. All I have to say is after having a manual 4406 for about 5 months now I am totally hooked.

As 410 told me, its effortless. When you need 4x4, you just reach down and click the stick back an inch or so. No more waiting for the shift motor, shift lights, wondering what its doing, if its actually in 4x4 or not. Simple, reliable, mechanical, strong, easy to operate... Thats what I call traction on demand :

 

[410Fortune]

plus the lights in the dash are cool

(pssst 4406 Low range is wicked low, this t case is a monster)

 

[Turdle]

I like my lever--

 

[Hokie]

plus the lights in the dash are cool

(pssst 4406 Low range is wicked low, this t case is a monster)

Yeah, haven't wired up my dash lights yet, I need to do that.

What is the 4406 Low gearing? This past weekend in Ouray we determined that it is definately lower than the 4405's the V6's have.

 

[Turdle]

Yeah, haven't wired up my dash lights yet, I need to do that.

What is the 4406 Low gearing? This past weekend in Ouray we determined that it is definately lower than the 4405's the V6's have.

It has to be a 3:1 (or close to that) reduction--
I hit the (stock) rev limiter at about 45 MPH!!

The dash lights are way cool!

All that time they sat there-hidden.
Think about that for a minute--

 

[Hokie]

Found this on www.offroadrangers.com

Low range: multiplies the available torque by 2.48 (Ranger BW1354) or 2.64 (F150 BW4406)

 

[Dan Whitaker]

You sissys and your lights. : Old school 4x4 didn't have idiot lights for the transfer case selector.

I just need to find me a t-case and get it in.

 

[Hokie]

You sissys and your lights. : Old school 4x4 didn't have idiot lights for the transfer case selector.

Well, its more for if someone else drive's the truck. And I've definately left it in 4Low on dirt and for around 10s I was wondering why I was turning so many RPM's

I just need to find me a t-case and get it in.

Yes, yes you do!

One thing they're talking about on Offroadrangers is did Ford only offer AWD with the V8's to keep the V8 torque + low range from eating the D35? Makes sense... one reason I won't be locking my front end.

 

[410Fortune]

they didnt have a 6 bolt t case that would fit under a gen II
AWD is a great way to fight the explorer's roll over rumors, and soccer moms love AWD

to me it seems like Ford wanted to shove the left over 5.0L's into the ex and a simple AWD full time t case fit the bill

Later they developed a 6 bolt t case for the 4r70w tranny, but ford wouldnt have stuffed it under the Gen II like we did, its huge

 

[techieman33]

The dash lights are way cool!

All that time they sat there-hidden.
Think about that for a minute--

It was probably just cheaper for ford to use the same cluster in all of the explorers/mountaineers

 

[gijoecam]

My understanding is they used the AWD case because the guts of the 44-05 couldn't take the monster torque of the 5.0. They've continuously upgraded the system such that the '02-ups now use the 44-05 behind the 4.6s (I think only in a single-speed case though...). Plus, I can't imagine the drivetrain behind the 302 in an EX in low range lasting very long. The axles and CV joints wouldn't like that very much.

 

[Turdle]

I guess what I meant to say was-out of all of the "major" umm, mods-lol, I have ever completed-this is by far the one that just felt right. The truck seems to want this. How can I say it--???

 

[CDW6212R]

Other than changing the gas tank, the electronic BW4406 is an easier swap than the manual 4406. I have a 98 which only needs the three control modules and the TC harness. It's on my short list, and if my 99 gives me trouble I'll swap that to a 302 AWD.

 

[410Fortune]

easier how?
It cant get much easier

the 4405 was used behind the SOHC which makes v8 like torque