98 Trans and Transfer case probs..

[CobraMountaineer]

Well, I figured out why my 4x4 won't work. I had the access panel off lastnight, and found that the cable was cut, and that it was nicely folded back and taped. Now that I have found the problem, does anyone know where or how I can hook it back up to the dash switch?

1998 AWD Merc Mounty

I have complete access to the trans door until I put in my new radio console and carpet. I need to know where to hook up what wires. I think I can splice into the body harness, but need to know what wires to go to. Any help would be appreciated.


Spin

 

[Turdle]

If you have a v8 there is no 4x4 function to repair. You have a full time ALL WHEEL DRIVE system. There are no wires at all going to your transfer case.

Someone must have come in before you and replaced your radio bezel with one from a 4wd truck. The AWD --2wd bezels without the 4w4 switch are a little hard to find.
All trucks have the harness for 4wd-the AWD trucks have them attached to a dummy plug in the rear of the AWD -2wd radio bezel

Hope this helps. Now you can do better things with your time.

 

[CobraMountaineer]

OK, why then is the wiring cut and laying on the tranny under the access panel. This is I guess AWD, 4High, 4Low. I guess I should have explained that when they did the motor swap, they used the body harness plug from the mustang, so there are more wires on the firewall side than the engine side.

 

[Turdle]

Once again. The awd transfer case has no wires, nor does it have a 4hi 4lo function.

 

[CobraMountaineer]

oK, LET ME GET SOME PICS, AND MAYBE THIS WILL SHED SOME LIGHT ON THE ISSUE. bbl

sORRY CAPS ARE ON...LOL


sPIN

 

[trj360]

you shouldn't have a switch on the dash either.

 

[CDW6212R]

Ouch, what do who do to the truck? It had a Cobra GT40P 302 engine with the better OBDII. What is up with the swap to a lesser OBDI, I'm going by your signature and thread descriptions?

What headers do you have, it came with GT40P headers with an EGR pipe? Welcome,

 

[CobraMountaineer]

Well, from what I am told. It has an E cam and no EGR ettached to the headers, i.e. cut off. I am going to post pics here in a few minutes. Tranny, engine, OBDI Plug etc. Lemme know what you all think...

 

[CobraMountaineer]

http://viewmorepics.myspace.com/ind...viewPicture&friendID=24076827&albumId=2864775

Here are the pics if you want to see them. A few things about the pics. I see a 1997 date on the intake plenum. The wires on the harness were spliced together. I have 2 wires that are not hooked up. Maybe to the EGR? RED/BLUE
White/Pink. Anyways, also look at the under hood fuse block. Notice anything different than yours? Like a few fuses missing and the tabs to install them? Just a few things that were a little off to me.

 

[CobraMountaineer]

Unless this was a V6 and they made the swap....mmmmmm....I wonder?? But it has all the belt stickers and such for the V8. I am lost here.... VIN Look up?

 

[CobraMountaineer]

I jst crawled out from under the truck, and found a 4406 transfer case. Pulled the dash bezel, and the 4wd selecter switch is hooked up to the body/dash harness. mmmmmm... dunno....

 

[CDW6212R]

It may take some time to figure it all out, but I suggest that you be patient and spend the time. If I did that(for whatever reason), I would probably work with it like that.

For you and if I got it that way, I'd suggest pulling all of the wiring from under the hood and using OEM 98 Explorer V8 wiring. It will be so much easier to work on, plus the gains of OBDII and original parts. If it does have the BW4406 then with little work you can make it work fine with that dash switch.

Does the brake booster have any sticker on the top of it? They will usually be labeled 5.0 for the V8 trucks.

I see that the AC is not usable due to the SN95 TB etc, I'd want the AC to work.

The wiring on the trans may be from a Mustang instead of an Explorer. That connector pictured doesn't look normal. It looks like a few fuses etc are missing from the PDB.

Why not start over, contact a great parts source here Kubiak. Ask him about the engine and trans harness, the under hood harness and PDB, the Explorer EGR pipe and elbow, TB etc. That stuff would not be hard to restore to stock.

The real question would become how much was altered in the dash wiring or the body wiring. Look closer at the three firewall connectors, and glance around under the dash. How much of that looks stock, or altered? If that seems to be in fine shape, I'd feel relief and start working on the rest. Karl Kubiak will likely have all that you need, even ask him about the AC lines. Regards,

 

[CobraMountaineer]

The truck runs great, and seems to be in full 4wd right now, the front shaft off the transfer case is locked, and it turns with the truck as well as the axels up front. I dunno, maybe later this year I can get a beater while this is being worked on. Might have a problem with rigging up a obdii with a dist. lol

Spin
Thanks for your help wish you lived on the Eastern Shore....


Again Thank you

 

[CDW6212R]

You would know it if the front axles were locked to the TC, I'd say you just felt the driveshaft. It will always be locked to the front wheels, but the center can't be locked on dry pavement. You would feel it in every turn.

Oh yes, I forgot you'd also need to get rid of the distributor. Put the OEM Explorer synchronizer back in, and the coil packs, they work better than a dist.
Here's what you want it to look like, a friend's 98 Explorer. Regards,

 

[CobraMountaineer]

you would know it if the front axles were locked to the tc, i'd say you just felt the driveshaft. It will always be locked to the front wheels, but the center can't be locked on dry pavement. You would feel it in every turn.

Oh yes, i forgot you'd also need to get rid of the distributor. Put the oem explorer synchronizer back in, and the coil packs, they work better than a dist.
Here's what you want it to look like, a friend's 98 explorer. Regards,

very nice........

 

[gijoecam]

You cannot get the system to work with the OEM Explorer wiring. It's not that simple. The 44-06's engagement and control system are completely different from the 44-05's. They are not at all compatible with each other.

Two options: Retrofit the transfer case controls from a push-button 1st-generation Explorer or equivalent Ranger (uses a partial-stand-alone setup), or convert it to a manual shift.

It's not locked in 4wd. If it was, it would buck and hop when cornering. You have a live front end. The front axles and driveshaft turn all the time.

-Joe

 

[CDW6212R]

Joe, I respect your opinions because you are usually very accurate. I thought that you knew this but the BW4406 has been installed in at least two 302 Explorers with the electronic controls(TOD). The V6 4WD system operates a TOD BW4406 exactly like it does the BW4405.

Aaron was the first to do it, about four years ago, and someone else did it last year. It works, not as you might assume, but exactly like the BW4405 does.

The GEM module of a 4WD 98-01 Explorer will operate a TOD BW4406 transfer case, with all of the same components used for the BW4405. There are a few parts to add which don't exist in a non 4WD truck, and Aaron documented all of those. I am intending on very very soon completing my conversion.

The BW4405(and BW4406 in this usage) both require a GEM, TOD, and 4WD module from the V6 4WD trucks. Some wiring has to be added also, the 4WD harness to the TC, and just two wires I believe for the dash/engine harnesses. The power wire is not in the V8 or 2WD trucks, and the other is a speed sensor wire I believe. Those wires are th last things I will need to get done.

The BW4405 functioning includes a electromagnetic clutch to achieve 4WD in two of the modes. The 4WD LOW setting is the only one which engages the shift motor, unlike how the GEM of the big trucks controls a bW4406. The BW4406 will work just like in the V6 trucks, 4WD HI will be electronically achieved with the internal clutch, not with the shift motor.

I do have a 1998 Expedition GEM and 4WD switch. I will look into the GEMS to see if the 4WD control section is identifiable, to separate it. I would like to be able to achieve the full 98 Expedition control of the BW4406, but not first. Regards,

 

[gijoecam]

Aack!! I'm getting my 44-06 and 13-54 swaps corn-fused... The 44-06 from the Expedition is the most likely candidate for that swap... My bad.... It was early... Sorry for the confusion...

I'll need to go back and re-read the thread before formulating a more helpful response to the problem...

 

[CDW6212R]

No problem Joe, I know little enough to get myself in trouble. I covered most of what he will need, Aaron's thread is very good.