BW4406 TOD swap to manual BW4406 | Ford Explorer Forums

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BW4406 TOD swap to manual BW4406

ninepin29

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June 9, 2017
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Year, Model & Trim Level
2000 Ford Expedition
Where to begin... so long, long time lurker (had a couple of Explorers at one time), but first time poster. I now have a 2000 Ford Expedition which has the Torque on Demand Auto4wd system.

Now as far as that goes, it seems the set up is similar to that of the Explorers. Case in point, the Brown Wire Mod write up in this site is what I used as a guide when doing the mod to my Expedition.

The current issue is with the engagement, or lack thereof, of the clutch in the transfercase so I'm at the crossroads: fix the current TOD BW4406 or do a manual BW4406 swap. However, the problem that I am running into is no one has done a transfercase swap on these trucks. Auto to ZF manual, motor swaps, SAS, etc., but no TC swaps.

I've been going over the many swap threads on here for the last week or so, and I think there are a lot of similarities between the trucks, especially the TOD set up. What I am trying to figure out right now is the speed sensors. I know the TOD BW4406 has a sensor in the front of the transfer case to read the front driveshaft speed and one in the rear for the same. Would I necessarily have to use both to get the transmission to work correctly?

With regards to the dash lights and the GEMs: If I don't really care about the dash lights, would it be as simple as pulling the fuse for the 4wd system, and leaving it off?

Sorry if these questions seem basic, or asinine, but I still don't know what I don't know and I'm trying to do as much research as possible before jumping into the deep end and doing the swap.

Thanks in advance for any info y'all can provide.
 






Hello ninepin29
Last November I did this swap on my 98 Expedition. I source all parts need from 97-03 F150 very strait forward. You would like to check it go to www.expeditionforum.com go to under construction click on The $200 98 Expy
 






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