AWD to BW4406 Electric Shift: Yes, its another BW4406 E.S. thread

[gijoecam]

Aack... Then the information I posted earlier is incorrect... The GEM from an Expedition should work OK then, as would a GEM from a V-6 Explorer.... You'll also need the transfer case shift relays from either an Explorer or an Expedition, and the switch from whichever vehicle you use the GEM from (though I haven't looked at the resistances to see if there's a difference between them)....

It's not insurmountable, but it's gonna be a pain... You'll need pin-outs of both the donor vehicle's connections as well as your own.... Yeesh! I wouldn't even know where to start!

 

[Mutineer]

Aack... Then the information I posted earlier is incorrect... The GEM from an Expedition should work OK then, as would a GEM from a V-6 Explorer.... You'll also need the transfer case shift relays from either an Explorer or an Expedition, and the switch from whichever vehicle you use the GEM from (though I haven't looked at the resistances to see if there's a difference between them)....

It's not insurmountable, but it's gonna be a pain... You'll need pin-outs of both the donor vehicle's connections as well as your own.... Yeesh! I wouldn't even know where to start!

Thanks GIJOE I am going to start with getting the wiring sorted out for mine and the donor, like you said.

It will be a long drawn out affair but I think oit will work out and Ill detail it all so others can have the info.

I have the switch from a 96 explorer, but it wont be hard to get the one from an Expedition if I need it.

Thanks, I knew this wasnt impossible as everyone makes it sound...

 

[gijoecam]

Let me do a little digging for you when I get to work tomorrow... should be a slow morning if all goes as planned...

Exactly what years are the vehicle and the donor transfer case out of? Can you find that out? From there I should be able to find you the pin-outs for each, schematics for both systems, to get you started. You'll also need to find the proper GEM from a used one, so once I can find all the possible candidates, it may be a matter of finding the one with the closest match.

 

[gijoecam]

My apologies... busy day at work for me today. Monday may not be so good either... Don't let me forget about this.

 

[Mutineer]

Thanks, I been out of town for a few days..

Tcase: 99 Expedition 5.4L

Switch: 1996 Explorer 4WD
The switch is the one thats built in to the radio Bezel, on the dash.

The motor os the one WITHOUT the 2 speed sensors...which is right for my Tcase since it doesnt have the sensors in it.

I think the GEM needs the "A" on it, as found in 96-01 4 WD Explorers... I havent seen much on the Expedition yet, Im going to get a chance to look on Monday if not sooner.

Thanks for your help, man!

 

[V8BoatBuilder]

Wow... Deja Vu...

Not sure if the search function has failed or..., but I covered all of this in my 4406 swap thread, when I pioneered this swap.

Start on Page 8.

http://www.explorerforum.com/forums/showthread.php?t=97181&highlight=T-Cases&page=8

The GEM issue is really simple. Don't make it over complex. You need a GEM from your year explorer (1998) that is from a 4WD vehicle. Done.

 

[V8BoatBuilder]

What the heck is this?

(the numbers dont bring anything up and my POS Haynes manual was written for 94 down and has caveats for 97 up...GRRRR)

I think it's Air-Bag related...

 

[Mutineer]

Wow... Deja Vu...

Not sure if the search function has failed or..., but I covered all of this in my 4406 swap thread, when I pioneered this swap.

Start on Page 8.

http://www.explorerforum.com/forums/showthread.php?t=97181&highlight=T-Cases&page=8

The GEM issue is really simple. Don't make it over complex. You need a GEM from your year explorer (1998) that is from a 4WD vehicle. Done.

I saw your thread, and it was a HUGE help. What Im working on now is a way to do it without the GEM...like what functions does the GEM provide for the 4WD circuits...

The GEM I need is elusive and expensive, and this is an option worth exploring IMO...

Im working on it, I have a relay block and I got it figured out I think, but Ive been out of town for work so much I havent been able to take whats on paper and apply it yet.

I get home Friday and the Contract has opened for a non traveling position at work...so I got my fingers crossed. if this works out I might finish this truck this decade...lol

 

[Mutineer]

I think it's Air-Bag related...

I think youre right. I unplugged it and it made no difference to running or driving, but I removed all airbag stuff so if it is airbag related, it wouldnt have done anything anyway...Oh well, its not hurting anything so Ill just leave it alone

 

[V8BoatBuilder]

Good luck on doing it without the GEM, I'm curious as to what you can come up with. But I also question why go through the work, what do you hope to gain?

Usually yellow connectors/tape/splitloom signify airbag components.

 

[Mutineer]

Good luck on doing it without the GEM, I'm curious as to what you can come up with. But I also question why go through the work, what do you hope to gain?

Usually yellow connectors/tape/splitloom signify airbag components.

didnt see any yellow...but its OK...

What I hope to gain is an option to the GEM. I think the GEM is a bad idea cooked up by manufaturing engineers to make money when it goes bad, since it controls so much they can charge a FORTUNE for it... I have a hard time wanting to spend 200 bucks or more on something that isnt broken...

if I can make it work without it, and refine my solution I might can make it alittle more affordable. As opposed to just buying the parts, Im actually building them, and gaining a very good intimate understanding of how the system works.

And on top of that, one day I'll get to say that I pioneered something to make it unique to my wants and designs, not that of the manufacturer. Which is why we build project vehicles in the first place, right?

 

[V8BoatBuilder]

didnt see any yellow...but its OK...

It's yellow on my truck

And on top of that, one day I'll get to say that I pioneered something to make it unique to my wants and designs, not that of the manufacturer. Which is why we build project vehicles in the first place, right?

Ditto. Keep us posted.

 

[Mutineer]

It's yellow on my truck

I think the connector that was on it was grey, and black...Ill look when I get home, if its yellow, then Ill know what it is.

Ditto. Keep us posted.

Will do, Im just sorry it takes so long for me to get anything done...hopefully soon itll work out.

 

[jds3403]

Hey man I think that I beat you to the punch, got my electric shift to work without the freakin GEM. I made a relay assembly using micro relays on a homemade Printed Circuit Board and the whole thing is half the size of the GEM controls my 4406 just fine, check out my thread search 4406 and mine is titled how to get a 4406 or 1354 to work or something similar and to those who say use the gem well this is worth it as I can say my own ingenuity created something that a team of engineers had to do. Makes you feel all warm and fuzzy on the inside kinda like a a grenade in an al queda cave just good all over.
check it out of you get a chance and hit me up with any questions, still need to post more pics though
Regards, me

ps pretty cheap to make too maybe 50 bucks or so

 

[jds3403]

Heres the title of the thread I started regarding this:

getting BW 1354 or 4406 or other elec transfer case to work

Regards, Jeff