AWD conversion to switchable transfer

[Astrok]

I have 2002 Merc AWD with a bad Transfer case. I am using it without the front drive shaft. Before winter I would like to install the Explorer switchable case. Has anyone done this? Does it just bolt in using same drive shafts?

 

[X6StringerX]

There are a few good write-ups on the forum. Its not as simple as just putting another transfer case in... there's quite a bit more involved. (new driveshafts, shift linkage for manual shifter, gas tank if you go with electric shift, etc.)

 

[CDW6212R]

I have not read of anyone changing the TC in a 3rd. gen Explorer. I know that since both TC options came in various models, you can swap them in. The only difficulty would be the 4WD wiring and modules. In my 98 Mountaineer the wiring is all in the body, and I can just add the 4WD switch, TOD module, 4WD module, 4WD GEM, and TC harness.

Research to see if you can find out where those components are located on the 2002+ 4WD Explorers/Mountaineers. If you can find that those wiring connectors are in your truck, then likely you can acquire those parts, and bolt them in. Good luck,

 

[X6StringerX]

I didn't even notice it was a 3rd gen in question. I haven't heard of anyone doing that either.

 

[CDW6212R]

A couple of members have asked in the past, but neither of those posted again to let us know what they learned.

 

[X6StringerX]

My gut feeling tells me it won't be simple if it can be done.

 

[Astrok]

I did research the site and their is no mention of 3rd gen conversions. I really like the truck in 2 wheel drive. The powertrain is so much quieter it is unbelieveable. I really only need 4 wheel 6 to 10 times in winter. I hoped I could bolt the 4 wheel case in and put a simple switch under the hood to shift into 4 wheel so I didnt need all the fool proof controlls about speed ect
I guess I will put a good set of snows on it and call it a day

 

[CDW6212R]

Go through one of the threads about swapping a BW4406 in place of the AWD of 96-01 Explorers. Other then the change of fuel tank and odd parts hunting(driveshafts, u-joints), it may be the same. The 3rd gen. trucks have the advantage of using the same transmission for 2WD and 4WD, plus the transfer cases both came behind both transmissions(5R55W/5R55E).

The wiring would have to be already in the existing harness. If it is there, then all that should be required is the addition of the mentioned 4WD parts. Regards,