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"Custom" Driveshaft for a 4406 and 4" Superlift on the Cheap

MountaineerGreen

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I did this some time back now, but it was buried 4 pages deep in another thread here.

I am going to copy most of the information here so others can find it.

Now that AMMO_HOOAH is getting a 4" Superlift and has a 4406, maybe others will get on the ball and do the mod too. :D
 


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MountaineerGreen

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Got the DS for the 96 sport to use the flange for my t case.

Found in the pile o driveshafts a perfect length front driveshaft for a Heep Grand Cherokee. The U joints are the same and it has a stock double cardan, but it uses a different style to connect to the t case

I am going to transplant the flanged double cardan from the Explorer driveshaft to the heep driveshaft. No need to get it shortened and it should work. I got both shafts for $81, so I should have a perfect front d shaft for not much cash. And as a bonus the heep front d shaft diff yoke is the same as my D35, so I don't need a conversion u joint.

From the top down:
Stock AWD D shaft
F150 D shaft cut down a little bit
Jeep front d shaft
Explorer Rear d shaft

driveshaftdouble_001_Small_.jpg


End shots same order just sideways - notice the jeep shaft has a different connection for the T case

driveshaftdouble_002_Small_.jpg


Yoke Comparisons: Left to right

Jeep
Stock D Shaft
F150 shaft with conversion joint

driveshaftdouble_004_Small_.jpg


Ford D shaft some what taken apart

driveshaftdouble_007_Small_.jpg


Ford flanged piece

driveshaftdouble_008_Small_.jpg


Jeep double cardan

driveshaftdouble_010_Small_.jpg


U joints- AZ only had these three. The brute force went in the middle u joint because it is impossible to get a grease gun in there anyway. The other two have zurks.

driveshaftdouble_011_Small_.jpg


Completed Double cardan

driveshaftdouble_012_Small_.jpg


Completed D shaft

driveshaftdouble_015_Small_.jpg


Comparison shot- the DC driveshaft is about 1/4" longer than my cut down F150 shaft. It just barely fits between the diff and T Case, but it is not bottomed out.

driveshaftdouble_019_Small_.jpg


Last picture- bolted up rear angle

driveshaftdouble_020_Small_.jpg



I am running 3 of the stock size u joints for my truck on a Jeep Grand Cherokee front D shaft with the double cardan from a Ford explorer sport.

No cutting or welding. Just a bunch of damn rusty u joints and 3 new ones. I took pictures but wont be able to upload them until tonight.

I took it on a road trip and no noise at all. At certain speeds a very small vibration in the floor, I suspect that is from the weights I left on the driveshaft. Now that everything is different, I don't need them.

The only people that need this are those with the 4406 AND a suspension lift. If you dont have any suspension lift a stock F150 driveshaft with a conversion u joint will work.
 












AMMO_HOOAH

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Very good info. I just wish I still had my front double cordon shaft:rolleyes:.
 




'97 V8

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'97 V8

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the 96-97 v8's had double cardan driveshafts in the front.
 








Turdle

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AMMO_HOOAH

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Serious?
I could swear Dans is a cv style--

I can't remember where the change happened, but some 95-97 had CV, and some had DC style. I'm not sure what I would have to do to make that fit.... I don't think the flange will bolt up to the 4406.
 




'97 V8

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the flanhe WILL NOT bolt up to the t-case sadly. THe 96-up until mid 97's(i'm sorry) had dc driveshafts. WHen the P headed expo's and mounty's came, they went to CV's.
 




AMMO_HOOAH

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the flanhe WILL NOT bolt up to the t-case sadly. THe 96-up until mid 97's(i'm sorry) had dc driveshafts. WHen the P headed expo's and mounty's came, they went to CV's.

LOL, in a little hurry there :p: That's what I figured with the stocker. I'm wondering if I could shim the rear mount point on the diff to get it to rotate down more, but well see what happens when I get the kit on.
 




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I spilled coke on my laptop keyboard...on the left side. My keys tend to stick.
 




Dan Whitaker

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the flanhe WILL NOT bolt up to the t-case sadly. THe 96-up until mid 97's(i'm sorry) had dc driveshafts. WHen the P headed expo's and mounty's came, they went to CV's.

Mine is a non P head & has a CV. The build date on mine is 12/96
 




'97 V8

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odd. You do know what that means though.....my mounty is older than yoooooourrrs neeeener neeener neeeeeeeeeener.
 




AMMO_HOOAH

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I'm thinking about using washers and a longer bolt on the rear mount for the diff to see if I can get it twisted down far enough to not need a DC shaft. If any of you guys foresee any issues don't hesitate to speak up.
 




CDW6212R

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Thanks Evan for the link to here, I had read this back then, but forgot the details.

Does the old Explorer DC front shaft have the same flange as the BW4406? I would think that it would be too small. I have my old 93 Explorer front shaft somewhere, I need to check its flange to see if it is just like the one which you used. My custom AWD shaft has the same front u-joint, no special part required either. Regards,
 


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MountaineerGreen

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I think a first gen driveshaft front double cardan driveshaft may bolt right in. I actually have one of those at my shop, I need to measure it vs. the driveshaft I have now. I think the flange will work- I know the sport rear driveshaft flange bolts up.
 




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