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AWD ---> 4x4 Manual T-Case Swap

410Fortune

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I am only going with 4.10 because this ex is my tow rig and will see long hauls on the highway, otherwise it would be 4.56 for me

I would say 20% may be a bit much, but its not far off. I think Mountain posted his MPG improvements didn't he?
2-3 mpg?

the conversion pays for itself as soon as you step on the gas IMO, its like a different truck, seriously

tire wear was a big factor for me, tires are expensive, awd = eats front tires
MPG opn the highway while towing in a straight line will be fantastic without the awd sucking up gas
highway passing power is WAY better, dont forget I also have a cam and bolt ons, but even a stock 5.0L would really benefit from this
steering is finally normal, no more struggle
the 4x4 feels really solid in this explorer, this is my first IFS truck and well, I am impressed with the 4x4 feel
the low range is LOW (have I said that before?) It makes the ex into a tank.
the coolness factor of having a V8 manual shift 4x4 even if nobody notices but you
the AWD t case is problematic after 125K miles, its a clutch its going to wear out
accelleration

those are the reasons, gas $$$, $$$ from parts also help. :p
 



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MountaineerGreen

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the conversion pays for itself as soon as you step on the gas IMO, its like a different truck, seriously

The difference is amazing, the AWD robs power it seems, mine tows much better with the different case. I would never go back AWD.
 






Hokie

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the AWD t case is problematic after 125K miles, its a clutch its going to wear out

My dad's Mounty has 125k on it, so I guess no one would want the AWD case...

I thought they were a gear driven case, kinda like a gear driven Torson limited slip?
 






410Fortune

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my current AWD case has 85K on it and I am having a hard time selling it. I sold my 150K mile case before I even had a chance to look at it, and I sold the 53K awd case I had in one day.

I think its just a matter of getting the word out and then waiting until somebody needs one.
Junk yards charge $300+ even with 150K miles, if it was working then they will sell it and somebody who needs their truck fixed will buy it.
 






MountaineerGreen

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My dad's Mounty has 125k on it, so I guess no one would want the AWD case...

I thought they were a gear driven case, kinda like a gear driven Torson limited slip?

I wouldn't be scared of the case if the truck hasn't been off roaded much, abused and such. My case with 120k on it was fine when I removed it. I sold it to a member on here for $200 shipped.
 






hybridhatchc1

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97 XLT eddie B
So i am also in the process of trying this conversion as i think my t-case took a shit on me... when i stomp the gas it goes but somthing popping... Anyway i am still alittle confused. would this be all time 4x4 or can i use the button center consol from a 97+ ex so u have option of 2wd,4wd, and 4wd low. any help would be appriciated.
 






hybridhatchc1

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97 XLT eddie B
Ok so i mis read the manual t-case... is it possible to use a electric shift case from any other explorer... i found BW4405 with the shift module for 600 freshly rebuilt... or is it just more cost effective and reliable for the manuel shift?
 






X6StringerX

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Try running a search for the electric shift case. If I'm not mistaken, you need to swap a sport gas tank into your 4-door in order for the shift motor to clear. Again, I remember reading some stuff, so run a search and you should be able to come up with some info on it.
 












pgdsm

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96 awd limited
well I did this swap a while ago with a electric case. Now the auto wrecker that I deal with have 3 of the bw4406 manuals twof them for sure have the vss in the tailshaft. I asked on price as I know some people would be interested. He sells them for quit a bit but will "give it to me for $500 cdn" so if anyone wants one then I coul arrange something to help you out, they are all sans shift linkage but there is a goodposibility that they have the linkages just have to wait till some snow goes away to find those.
 






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