awd to 4x4 in 2002 mountaineer

[exigent]

I have an 02 mountaineer. 4.6 awd. Tcase locked up a while ago and I pulled the front d/s to get me by. Well, the 5r55w I rebuilt 75,000mi ago broke the reverse band. I found a newly rebuild trans for cheap enough I just bought it instead of another rebuild. Plus I need the truck running by the 14th so I can go hunting. Anyways, I'm swapping the trans and it came with a 4x4 case bolted to it. I planned on selling it but then it hit me I could kill two birds here and ditch the awd. The case is presently in 2wd mode. Am I missing something big here or could I not install this case and drive it in 2wd until I sort out the controls?

I am a professional race car mechanic so I have the ability to make the missing harnesses and source the connectors. My experience allows me to do non standard things like this all the time so please don't dismiss this as too difficult. If you think it is, why specifically? I see from the shop manual I'd need at minimum the 4x4 module, switches, and a custom harness to the case, as well as a custom harness to the gem,pcm, and pdb. Like I said I have access to connectors and pins to make the harnesses I understand the pcm may need to be swapped as well or perhaps I may get around that with a reflash.

I'm going to attempt it either way unless you guys have some inside knowledge. If anyone has tried this please let me know. I found the threads on this subject but they all pertain to older vehicles. Let me know if anyone has tried this. Either way I plan to document the exercise for the masses. I may not go so far as a how to but I will at least supply the details so a good tech can sort it out.

Thanks in advance guys.

 

[traveler]

There are extensive threads on how to convert Gen II explorers from AWD to 4WD. I don't know how much of the information will apply to the 02 platform though. Might be worth looking into though.

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[exigent]

My search foo only found guys using manual shift cases. While that would be easier in some respects, especially since the gen2 had provison for it I believe. ?. I have a gen 3 electronic tcase. Looks like im just going to have to try it and see. Like I said in my original post its in 2wd mode rite now so I have some time to goof with it.

If you can find any posts concerning an electronic shift swap please let me know.

 

[traveler]

I believe there are a few folks who have converted their Gen II to electronic shift 4WD. It does require extensive rewiring and module swaps. (Well.. to me they are extensive, to others maybe not so much). None of the Gen II explorers had manual shift. The swaps being done involve using F-150 tcases and shifters, and cutting a hole in the floor.

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[Duranged84]

I'm working on the exact same swap. Have you gotten any farther with yours? I had a complete running/driving parts truck, so I lucked out with getting the entire dash harness, 4wd module, harness to transfer case, ecm, security module, key, etc. I'm just trying to figure out if swapping the dash harness and adding 4wd module and tc harness is all its going to take. I have power to the 2 4wd fuses in the under hood fuse block so wondering if it'll plug and play or need a reflash, or more under hood wiring I didn't get. Which, now that I think about it, I should have it. The engine and trans harness came from the donor and I pulled the remaining battery cable/accessory harness, just not the front body harness(lights, etc). The engine, trans, and harnesses, have all been in with no issues and no warning lights for almost 5k miles. Soon as I get time to change the now grinding rear end and pull the dash again, I'm diving into the 4wd wiring.

 

[Duranged84]

exigent, Are you still around?