Converting a 2WD to 4WD.

[shambug]

What would be the best way to convert a automatic 3.0L 92 2wd aerostar to a 4wd. Im not interested in the E-4wd system, I would like manual control. The 4wd would not be used often or for long periods or stressed to the max just help out in the mud/snow. Low range would be nice but not necessary. I understand that this is no small undertaking. I would like to know everything that will be necessary so I can start pricing everything out.

From what I understand, I can swap in a 4wd ranger transmission. Then swap out the front end from a awd aerostar. Is this correct at all?

 

[BrooklynBay]

Welcome to this forum! You might be better off swapping all of the parts from a 4WD Explorer or Ranger. The 3.0L engine uses a different bellhousing on the transmission than the 4.0L. The extension shaft is different on the 2WD transmission, and doesn't link with a 4X4 extension housing without swapping the extension shaft internally.

 

[loosenut349]

The front diff. on the AWD aerostar does not have locking hubs, It is full time, So I don't think you would use that if you were looking for manual control.
Like Brooklyn Bay said, You would be better off swapping parts from 4WD Ranger or Explorer.

 

[shambug]

The extension shaft is different on the 2WD transmission, and doesn't link with a 4X4 extension housing without swapping the extension shaft internally.

So to understand you correctly my auto 2wd transmission can be rebuilt with the 4wd extension shaft and allow for 4wd without an engine swap?
Not that that is the best solution just asking if it is a possible solution.
Would not a 3.0L ford ranger A4LD transmission mount correctly?
Lots of explorers and rangers around in the junk yards around here. Ill be doing lots of measuring over the next couple weeks just wanted a good starting place if anyone has done or looked into doing this.

 

[BrooklynBay]

There are many threads about swapping the output shaft on this site. I know that it was done in the Explorer. The A4LD has many interchangeable parts for various configurations but is a lot of work to rebuild just to swap the output shaft.

 

[shambug]

So the only other option is full engine/transmission/front end swap from a ranger or explorer.

 

[shambug]

I have decided that I am going to try a 4.0L ranger transmission and switch bell-housings. I will have a shop or someone with the tool help with the pump.