Auto Lockers in AWD diffs?

[Mbrooks420]

Dig it!

 

[CDW6212R]

You will want the BW4406 transfer case first thing, everyone loves it versus the AWD TC.

 

[410Fortune]

nice looking rigs
I would so ditch the awd and install a 4406 in that truck
NIGHT and DAY difference on and off road with true 4wd. For what you plan to do with this thing the 4x4 conversion is right up your alley
The 4x4 conversion will pay for itself in two sets of those expensive 34" tires....awd will chew the front tires up more quickly

 

[DirtyDeezl]

Are we talking either/or electronic shift or manual shift transfer case? They dont seem hella expensive by itself, but what type of accessorial peripherals have to be bought along with it to do that xf swap?

 

[Mbrooks420]

You can do either. Manual is easier of course. You can even go crazy and do an automatic 4wd version.

 

[410Fortune]

BW4406 transfer case manual shift from, 97-2014 4.6 v8 or 4.2 v6 F150's
Shifter and linkage
front and rear driveshafts
conversion U joint for the front
May have to have rear shaft built for proper length into explorer
Mercon III fluid (or Mercon LV or whatever ATF you want to run in there, just do not run Mercon V in the t case)

Conversion will pay for itself in your first set of tires, wheel bearings and fuel mileage savings

To install the ESOF version you would need to add some stuff like the dash switch, the through body t case wiring harness, a 4406e shift t case with shift motor and a 02+ Motorolla stand alone 4x4 control module all would need to be wired into your 5.0 sploder

 

[DirtyDeezl]

Lol. In due course this may happen. Ive been purging what little money ive had already.

 

[CDW6212R]

The old Mercon ATF is still available as the same old Dexron III, most all of it still is labeled as meeting Mercon standards. That was a Mercon I, there never was any Mercon III or anything between Mercon I and Mercon V. The Mercon V was the new upgrade to Mercon I, and later they discovered it was destroying transfer cases, thus never use Mercon V in any transfer case. That's a big subject still, everyone wants to tell you you have to use the new high dollar special TC fluid, XL-12 was the first replacement($25 a quart), and now some other new TC fluid. From what I can tell, all of them are no better than the first Mercon I fluid, still available(not licensed), called Dexron III still today, everywhere.

I found the Valvoline TC fluid recently, and I like Valvoline a lot, I got a case of six for $30 total from Amazon. That's cheaper than all other TC fluids except the Dexron III.

 

[CDW6212R]

...

To install the ESOF version you would need to add some stuff like the dash switch, the through body t case wiring harness, a 4406e shift t case with shift motor and a 02+ Motorolla stand alone 4x4 control module all would need to be wired into your 5.0 sploder

Have you heard of issues with using the OEM V6 4WD GEM module to run those TOD BW4406's? I'm still planning to go to the TOD TC, and I have the OEM V6 modules to do it(GEM, 4WD, TOD). The extra wire(s) for the V8 to run the TC system was the one thing I hadn't plotted out yet.

 

[ST Bob]

The old Mercon ATF is still available as the same old Dexron III, most all of it still is labeled as meeting Mercon standards. That was a Mercon I, there never was any Mercon III or anything between Mercon I and Mercon V. The Mercon V was the new upgrade to Mercon I, and later they discovered it was destroying transfer cases, thus never use Mercon V in any transfer case. That's a big subject still, everyone wants to tell you you have to use the new high dollar special TC fluid, XL-12 was the first replacement($25 a quart), and now some other new TC fluid. From what I can tell, all of them are no better than the first Mercon I fluid, still available(not licensed), called Dexron III still today, everywhere.

I found the Valvoline TC fluid recently, and I like Valvoline a lot, I got a case of six for $30 total from Amazon. That's cheaper than all other TC fluids except the Dexron III.

Mercon was replaced by Mercon V. (Mercon and Dexron III are NOT the same fluid). The original Mercon is no longer available. You guys are correct in that you should NOT use Mercon V in a transfercase. XL-12 has been replaced by Mercon LV. Ford parts manager here. If I can help just let me know.

 

[CDW6212R]

...Mercon and Dexron III are NOT the same fluid...

You just stated the same information I did in less words, well done. I did not say they were the same fluid.

Most knowledgeable car people know that most all Mercon and Dexron III came in the same bottle, by many manufacturers. Nobody knows why that was the case, but it was. When you bought Mercon, the bottle had a slash and the words Dexron III next to it. Most people think it was Mercon III, because the Dexron III was printed right there on all bottles with Mercon on it.

Dead subject, drop it. We all know Mercon I is not made anymore, but we also know that virtually all Dexron III met Mercon I specs, and still most of it lists it on the label. So feel free to dog the Dexron III makers, but the rest of us will learn what works, and use it. The Mercon I is available, you just have to hunt for it.

It's a sore subject for me because of the many stupid things Ford does. The AOD transmission is not supposed to have Mercon V put in it, but dealers have been telling people to do that. The AOD came out just before Mercon, and that was then the recommended fluid. But the AOD is not made to handle the slicker Mercon V, but Ford as always, made a unilateral recommendation to use Mercon V in place of all Mercon applications.

Bingo, dumb mistake, thus the transfer case issues created by Ford(Mercon V in TC's). The AOD is the same way, Mercon V is too slick for them, though it hasn't become a big enough problem yet(AOD's are fewer and fewer now due to age). That's a diminishing problem that Ford is going to ignore for that reason, fewer to complain about it.

Mercon is fine for the AOD, Mercon V is not.

 

[ST Bob]

You just stated the same information I did in less words, well done. I did not say they were the same fluid.

Most knowledgeable car people know that most all Mercon and Dexron III came in the same bottle, by many manufacturers. Nobody knows why that was the case, but it was. When you bought Mercon, the bottle had a slash and the words Dexron III next to it. Most people think it was Mercon III, because the Dexron III was printed right there on all bottles with Mercon on it.

Dead subject, drop it. We all know Mercon I is not made anymore, but we also know that virtually all Dexron III met Mercon I specs, and still most of it lists it on the label. So feel free to dog the Dexron III makers, but the rest of us will learn what works, and use it. The Mercon I is available, you just have to hunt for it.

It's a sore subject for me because of the many stupid things Ford does. The AOD transmission is not supposed to have Mercon V put in it, but dealers have been telling people to do that. The AOD came out just before Mercon, and that was then the recommended fluid. But the AOD is not made to handle the slicker Mercon V, but Ford as always, made a unilateral recommendation to use Mercon V in place of all Mercon applications.

Bingo, dumb mistake, thus the transfer case issues created by Ford(Mercon V in TC's). The AOD is the same way, Mercon V is too slick for them, though it hasn't become a big enough problem yet(AOD's are fewer and fewer now due to age). That's a diminishing problem that Ford is going to ignore for that reason, fewer to complain about it.

Mercon is fine for the AOD, Mercon V is not.

Mercon and Dexron III are similar. Mercon V took the place of Mercon so it is recommended for the AOD. One of the dumb things is that in the Motorcraft literature it states not to mix Mercon and Mercon V. Not sure how you avoid that if you are putting it in a transmission.

 

[BUXTER]

I went with Valvoline Full Synthetic Transfer Case Fluid in mine at 76K miles - Old Merc looked brand new with no debris when I filtered it thru white shop towel - Label says good for the OLD "Dex/Merc, XL12, GM Auto Trac, ATF+4, ETC" - Kinda pricey but u use less than 1 Qt so...

 

[SWIGIN]

I don't understand guys saying not to lock the front diff if you drive in snow.

I live in PA and drove a 79 bronco 18 years with a front limited slip and it was more of a handful then my EX with a Lock Right.

The Limited slip will push in corners 100% of the time whereas the lunchbox locker goes open when you coast. I find it MUCH nicer to drive in bad weather then the LS.

Of course like I said I had 18 years practice driving in bad weather knowing 100% that it'll push in every corner so maybe that's why I don't mind it but it does seem better.

I also agree that a 4406 swap should be apart of this as well. You can always pop it in 2wd if you have a real problem pushing.

 

[Mbrooks420]

I don't understand guys saying not to lock the front diff if you drive in snow.

I live in PA and drove a 79 bronco 18 years with a front limited slip and it was more of a handful then my EX with a Lock Right.

The Limited slip will push in corners 100% of the time whereas the lunchbox locker goes open when you coast. I find it MUCH nicer to drive in bad weather then the LS.

Of course like I said I had 18 years practice driving in bad weather knowing 100% that it'll push in every corner so maybe that's why I don't mind it but it does seem better.

I also agree that a 4406 swap should be apart of this as well. You can always pop it in 2wd if you have a real problem pushing.

No one suggested a limited slip up front. It would surely be worse.

 

[RangerX]

Sorry to continue the mercon tangent, but this is the first I’ve heard of the transfer case issue with mercon v.
Both my trucks call for mercon in the manual trans and the tcase, and I’m just wondering what damage does mercon v do to tcases but not a manual transmission? Or is it also not recommended for that?
I have not bought it, but just wondering. The guts in a manual and a tcase seem similar enough to make me ask, thanks.
For the record, I’ve been buying super tech atf from Walmart for probably 20 years, says for dexron and mercon applications.

 

[gmanpaint]

Locked front in snow isn't a problem. Locked front on the road is.

If the road is covered with snow completely, that's one thing, but If it's patchy covered roads, you don't want to locked going from snow, to pavement. That breaks stuff. Lol

The LS will be harder to handle in snow covered roads, but if it grabs dry road while spinning a tire from snow, your less likely to break stuff. Especially when the wheels are turned.

I have had a front lock right in a cad axle for about 10 years, and have never ever once put it in 4wd on the road since installed. Maybe it's just me, but I really dislike snapping half shafts in the dead of winter, miles from home.

Heck, I have a 1st gen ex that is also locked front and rear. Same goes for it. Solid snow covered roads, 4wd no problem. Patchy covered, not a chance. If you live in an area, that roads aren't treated, and plowed right away, I can understand using it more. Not so in populated areas.

 

[410Fortune]

@RangerX it seems some of us old school dudes missed the boat on the whole do not run Mercon V in a t case thing. But it is true, mercon V is too slippery for a slush box or chain driven t case.... unfortunately for me I blew up two t cases this way, one in my BII and one in a customers truck.
in 98 or so all Ford dealers got rid of all conventional fluids and mercon V was put in everything. Sometime later it was decided that mercon V cannot be used in our t cases and it was printed on the bottle.........I must have been asleep or something because Mercon V was the only ATF I bought for like 10 years....so any 1354, 4405 or 4406 t case I worked on got mercon V.... and most of them never had any issues.

Then I finally from this forum and many other ranger boards learned you cannot run it in our t cases. Then I realized those two t cases that blew up on me were filled with mercon V... a spark went off in my head, there was some smoke and a headache. Then after that I got happy because Mercon V is pricey! So knowing I could use plain old ATF in my t cases again made me happy........ now I keep Mercon III in stock (or really any older atf, like Dextron will work too)

So you should NOT put V in your t case.
Now the battle rages on about what fluid you SHOULD run in those cases....silly to argue about it. Anything but Mercon V will work really, even the newer stuff LV or whatever is okay in there. Ford started selling "TRANSFER CASE FLUID" which is basically Mercon III


@CDW6212R
Using a GEM module to control the TOD t case is about your only option isn't it? Or just run the brown wire on a switch? I am not real familiar with making the TOD system work electronically. I read about the brown wire mod years and years ago. These 4406 t cases we run are TOD compatible...So it would be cool to make one work!
My friend Rich ( @Starkman ) who races his Mazda B5000 on ice and dirt rally with a stock 5.0 AWD t case, really wanted to persue the whole lets run a 4406 t case and get the TOD system working with me, but that was right when we moved from CO to ID so I never got tooo deep into that conversation. I know he pretty much got it sorted out, not sure he ever installed it but seemed to have it working on paper. Maybe he will chime in here.

I know the info is out there. Basically when enough wheel slip is detected the TOD clutch is activated and for a short moment you get 4wd, correct?
Should not be tooooo hard to do.
You can use a Gem to control that for sure..... I have seen some of these builds incorporate two gem modules, one to handle the truck and one to handle the 4x4 system or speedo corrections or whatever is needed.... you can piggyback them into the same truck.

 

[CDW6212R]

...
@CDW6212R
Using a GEM module to control the TOD t case is about your only option isn't it? Or just run the brown wire on a switch? I am not real familiar with making the TOD system work electronically. I read about the brown wire mod years and years ago. These 4406 t cases we run are TOD compatible...So it would be cool to make one work!
My friend Rich ( @Starkman ) who races his Mazda B5000 on ice and dirt rally with a stock 5.0 AWD t case, really wanted to persue the whole lets run a 4406 t case and get the TOD system working with me, but that was right when we moved from CO to ID so I never got tooo deep into that conversation. I know he pretty much got it sorted out, not sure he ever installed it but seemed to have it working on paper. Maybe he will chime in here.

I know the info is out there. Basically when enough wheel slip is detected the TOD clutch is activated and for a short moment you get 4wd, correct?
Should not be tooooo hard to do.
You can use a Gem to control that for sure..... I have seen some of these builds incorporate two gem modules, one to handle the truck and one to handle the 4x4 system or speedo corrections or whatever is needed.... you can piggyback them into the same truck.

I thought you were here when (Aaron I think) put the TOD 4406 into his green 98 Mountaineer. That TC will work the same way as the BW4405 in 4WD V6 Explorers, using the same three modules. Aaron discovered the one missing wire but he didn't document that one item. His thread is or was the prime one to read for swapping any BW4406 in place of the AWD, minus the shift linkage etc. That's where the drive shafts were first documented etc, and all other manual swap threads referred to his thread because of the details he has in it.

The wiring is all in the dash of my 98's I think, the TOD and 4WD module connectors are there. I think that one wire you mentioned in the trans harness is not there, and possibly a power wire mentioned in Aaron's thread.

The key was to swap a Sport gas tank in, due to the shift motor that conflicts with the tank mount. I took pictures of my 98 Mercury's gas tank the last time I replaced the pump. I also had my old 93 Limited plastic tank, 22 gallons of course.

I didn't get to doing the tank yet, but that was my first planned step. Look at these two tanks below, the two I mentioned above. They are way different in length, but the plastic style hold much more gas. Both are 22 gallon tanks and mount with the same strap.

 

[Starkman]

@RangerX it seems some of us old school dudes missed the boat on the whole do not run Mercon V in a t case thing. But it is true, mercon V is too slippery for a slush box or chain driven t case.... unfortunately for me I blew up two t cases this way, one in my BII and one in a customers truck.
in 98 or so all Ford dealers got rid of all conventional fluids and mercon V was put in everything. Sometime later it was decided that mercon V cannot be used in our t cases and it was printed on the bottle.........I must have been asleep or something because Mercon V was the only ATF I bought for like 10 years....so any 1354, 4405 or 4406 t case I worked on got mercon V.... and most of them never had any issues.

Then I finally from this forum and many other ranger boards learned you cannot run it in our t cases. Then I realized those two t cases that blew up on me were filled with mercon V... a spark went off in my head, there was some smoke and a headache. Then after that I got happy because Mercon V is pricey! So knowing I could use plain old ATF in my t cases again made me happy........ now I keep Mercon III in stock (or really any older atf, like Dextron will work too)

So you should NOT put V in your t case.
Now the battle rages on about what fluid you SHOULD run in those cases....silly to argue about it. Anything but Mercon V will work really, even the newer stuff LV or whatever is okay in there. Ford started selling "TRANSFER CASE FLUID" which is basically Mercon III


@CDW6212R
Using a GEM module to control the TOD t case is about your only option isn't it? Or just run the brown wire on a switch? I am not real familiar with making the TOD system work electronically. I read about the brown wire mod years and years ago. These 4406 t cases we run are TOD compatible...So it would be cool to make one work!
My friend Rich ( @Starkman ) who races his Mazda B5000 on ice and dirt rally with a stock 5.0 AWD t case, really wanted to persue the whole lets run a 4406 t case and get the TOD system working with me, but that was right when we moved from CO to ID so I never got tooo deep into that conversation. I know he pretty much got it sorted out, not sure he ever installed it but seemed to have it working on paper. Maybe he will chime in here.

I know the info is out there. Basically when enough wheel slip is detected the TOD clutch is activated and for a short moment you get 4wd, correct?
Should not be tooooo hard to do.
You can use a Gem to control that for sure..... I have seen some of these builds incorporate two gem modules, one to handle the truck and one to handle the 4x4 system or speedo corrections or whatever is needed.... you can piggyback them into the same truck.

I never went anywhere with that thought. I did install the manual 4406. It was so easy with the smaller gas tank in the truck. It is now so much fun to burn the rear tires!

My experience with the AWD box was that it would slip like I wanted and go into oversteer but only for a short time until the speed increased and it would lock back up and the truck then understeers. So I wanted to be able to use a steering brake in the rear and when I would pull the brake lever the box would open from 4x4 and I could get the truck to back into the turn and when I release the brake the box would re-engage 4x4 and power out. The more I looked at how the shift motor works it would not be able to act quickly enough.