How to: Convert V8 AWD to BW 4406 Manual Shift- A how to thread

[Turdle]

I did bring a f150 mount home only to see the studs were different and I didn't have time to mess with it.

 

[CDW6212R]

The aftermarket mounts look taller than our stock trans mounts, which is why I settled on the new Ford part. It sounds like it's the right time to compare those dimensions more closely. The aftermarket stuff is likely going to be for Mustangs though, so hopefully they will mount to the trans at least.

 

[410Fortune]

I may attempt to pick up the transfer case, itself with its own mount

I will be keeping rubber/urethane mounts on this truck.. its my daily driver / family hauler / road trip tow rig my engine mounts have 80K miles on them, the trans mount is like 5 months old... new from Napa $18

there must be a way to support transfer case , new x member? support from the existing gas tank bracket? would be simple to weld something to the gas tank support to pick up a couple tabs on the 4406, use some sort of rubber mount between them? just thinking out loud here

 

[Turdle]

I wonder if that little eyelet hole right near the transfer case skid plate could be used for an adjustable bushed link thingy to the frame? this would allow some weight to "hang" by it--???

 

[V8BoatBuilder]

Curious what we can come up with... I've put on two trans mounts since my 4406 swap.

 

[soon2bsick]

okay so I've been trying to round up prices from cart-parts.com and when I go to check out transfer cases on an f150 (2000) it lists theses options:

manual shift, ID XL34-7A195-AA
electric shift, ID XL34-7A195-BA
electric shift, ID XL34-7A195-BB
electric shift, ID XL34-7A195-BC
manual shift, ID XL34-7A195-AB
manual shift, ID XL34-7A195-AC



*Scratches head*

 

[my pos mounty]

On the first post of this thread, it lists the years of the Ford F150 4x4 transfercase you can use as 1997-2003. What I did was look up the 2003 model year. It lists 3, (2 manual, 1 electric) And According to this thread the difference in them are speed sensors (other than the obvious). You do not need this speed sensor so it doesn't matter where the speed sensor is.


manual shift, ID XL34-7A195-AB
manual shift, ID XL34-7A195-AC
electric shift

 

[Nate_V8]

Ok, so what I've seen is,

97-03 manual T-case
front and rear DS out of a 5.4 Expy
about $100 in parts for the linkage from ford.
hardest part is I need to cut a hole in the floor? Are there any annoying bugs? or did you guys work them all out?

How involved was this? How long did it take you guys on average?
and in 2WD is 100% power going to the rear?

Just need to know how long because it is my DD and I'm interested but wary.

Btw, any confirmed gain in MPG and any ET gains?

 

[hmorris]

is it possible to do the same to a 4wd 99 sport? it has the electronic think id love to have manual

 

[Glen4X4]

is it possible to do the same to a 4wd 99 sport? it has the electronic think id love to have manual

You would have to go to a BW 1354 manual from a first gen ex or ranger. Search around the forum there's many who have put the 1354 into their 2nd gen 4.0's

 

[CDW6212R]

is it possible to do the same to a 4wd 99 sport? it has the electronic think id love to have manual

No one has yet done the Sport, but I think it can be done. The gas tank clearance is the only issue, the big BW4406 is close in the 4dr's. In a 2dr, it may take more work like I'm trying to do to get an electronic 4406 to work with a big tank.

Ask the guys who know the trucks better like Jamie, about the length differences between the 2dr and 4dr. Then you figure how much you need given how much clearance others have had with the manual 4406 in there trucks.

 

[gavin]

No one has yet done the Sport, but I think it can be done. The gas tank clearance is the only issue, the big BW4406 is close in the 4dr's. In a 2dr, it may take more work like I'm trying to do to get an electronic 4406 to work with a big tank.

Ask the guys who know the trucks better like Jamie, about the length differences between the 2dr and 4dr. Then you figure how much you need given how much clearance others have had with the manual 4406 in there trucks.

it hasn't been done... because the Sport never came with a V8, and the 4406 won't bolt up to the V6 (without a custom adapter of sorts, anyway) :

 

[CDW6212R]

it hasn't been done... because the Sport never came with a V8, and the 4406 won't bolt up to the V6 (without a custom adapter of sorts, anyway) :

I know he's talking about a V6, that would be a waste of so much work IMO. I'd do the V8, the parts are so much cheaper and better to start with.

For the V6 he's stuck with those other TC's.

 

[V8BoatBuilder]

Like the tried-and-true 1354M, still in Rangers today!

 

[nobodyspecial]

I see in the first post, it says 200? for the expedition rear shaft. I am looking at one from an 04 expedition 5.4 4x4. Does anyone know if that is too new? what is the age range for expedition rear driveshafts or are they all the same from 97 till now?

 

[MountaineerGreen]

To be safe, I'd stick to the old body style Expedition, the newer body style went to IRS and the driveshaft is likely a different configuration and length.

 

[nobodyspecial]

Oh yeah... Forgot about the IRS, good call.

 

[77'cj7]

I'm currently finishing up this swap in my ranger, and had a couple things that could be added into the original post.

First, the oreillys part number for the conversion joint is Precision 353.

Second, the earlier full size cases (1356, 1345) won't fit. They are over an inch and a half wider on the drivers side, so they hit the frame. I was trying to run a bronco 1356 for a flanged rear output.

 

[Orangeoutlaw]

Does anyone know the color of the wires for the 4x4 lights at the gem for a early 1997 Mountaineer (manu in 1996)

 

[turboexplorer]

Yes, give me a sec and i will search for it and post the link on here. Haha, thought it was in this thread. Start looking at post #18 in this thread and you will find it. Thats exactly what i did with mine and it has worked perfect! Thanks again to those that figured it out!