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Well, the ranger bumper fell through, dude meant to set it as a pickup only, won't ship it all the way from Wisconsin down here to Florida, so that's a bust. Back to square one.
 



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How difficult, much, and long do you think a manual t-case install would be? I'd be doing all three, the 5.0 v8, the transmission for it, and the 4406. Better gas mileage too since I can make it an actual 2wd, as well as it should help with the lack or power to the tires that I currently have. I refuse to swap to a V8 if I can't have my 4wd, besides I hear the awd tends to eat up the front tires, so yeah, this is worth it to me. I'd have to see about a shop doing it since I ain't got the place or equipment to do an engine swap at the very least, so what are y'alls estimates and opinions?
And yes, I've been searching and reading threads on this, still am actually, want to fully have a grasp on this first.
 


















So, at the local junkyard, transfer case sells for about $130, so with all of the other parts, probably just a bit over $200. Not including the whole V8 and trans swap, hopefully do everything at the same time so I don't have to bother with getting an awd transfer case to hold me over till I can do the 4406 swap. Now, I guess I'll have to figure out maybe a donor exploder with the V8? Man this is going to be the death of me..incredibly difficult to plan. What about throwing the 4406 on the 4.0 sohc? Think that's a possible thing? Just to hold off on the V8 swap, rather have a place before I try that so I can actually store a donor vehicle and work on this one. Probably not likely to work, but anything to get my wheel power back, plus the advantage of mileage from 2wd. Could try swapping my gears, original plan, but I'd rather stick to these 3.73s if I can, work fine and even my brother's suburban proves that.
 






So, at the local junkyard, transfer case sells for about $130, so with all of the other parts, probably just a bit over $200. Not including the whole V8 and trans swap, hopefully do everything at the same time so I don't have to bother with getting an awd transfer case to hold me over till I can do the 4406 swap. Now, I guess I'll have to figure out maybe a donor exploder with the V8? Man this is going to be the death of me..incredibly difficult to plan. What about throwing the 4406 on the 4.0 sohc? Think that's a possible thing? Just to hold off on the V8 swap, rather have a place before I try that so I can actually store a donor vehicle and work on this one. Probably not likely to work, but anything to get my wheel power back, plus the advantage of mileage from 2wd. Could try swapping my gears, original plan, but I'd rather stick to these 3.73s if I can, work fine and even my brother's suburban proves that.
The 4406 will not work on the 4.0. You will have to get a 1354 to get out of the Tcase you have now. I have a 1354e in my 97 and it works pretty good.
 






The 4406 will not work on the 4.0. You will have to get a 1354 to get out of the Tcase you have now. I have a 1354e in my 97 and it works pretty good.
How much power did that bring back? As well as how much modifying I would I need to do the 4406 later then? Fit it in the same hole?
 






How much power did that bring back? As well as how much modifying I would I need to do the 4406 later then? Fit it in the same hole?
The 4406 manual will fit but from what I have been reading you will have to get a sport fuel tank as the Manual 4406 will not fit with your normal fuel tank. Also with me I never really drove my Ex with the 4405 and with stock tires. I have always had the 33's and the 1354. But from my other Ex I did this to it seemed to drive a little better. Also I think my old motor was not as good as what it was supposed to be. So once I get my new one running will see how things are then. hoping it will be better. To put in the 1354e I just hooked up the wires from the 4405 plug to the 1354 wiring and I can switch to 4x4 still with my switch. Now the 4x4 lights blink every once in a while but I just ignore it. I have had no issues with it. I am hoping to get a manual 1354 some day and have it that way for my Ex.
 






The 4406 manual will fit but from what I have been reading you will have to get a sport fuel tank as the Manual 4406 will not fit with your normal fuel tank. Also with me I never really drove my Ex with the 4405 and with stock tires. I have always had the 33's and the 1354. But from my other Ex I did this to it seemed to drive a little better. Also I think my old motor was not as good as what it was supposed to be. So once I get my new one running will see how things are then. hoping it will be better. To put in the 1354e I just hooked up the wires from the 4405 plug to the 1354 wiring and I can switch to 4x4 still with my switch. Now the 4x4 lights blink every once in a while but I just ignore it. I have had no issues with it. I am hoping to get a manual 1354 some day and have it that way for my Ex.
I actually read a few and the manual 4406 can most often fit with the larger fuel tank, remove the plastic around it or trim it and possibly trim the mount, but otherwise it fits. The electric will not fit without the smaller tank, but I like the idea of engaging the 4WD myself anyway, I'm sure it's in gear more than the switch. My brothers suburban came with a manual 4WD, got to say its nice. Think I could literally take a shop both my truck and a donor and say have fun with the V8 swap? Be quicker and easier as long as I can afford it! lol
 






I totally get what you are saying. I would like a V8 swap but I think I am gonna run my sohc and see how many miles I can get out of her this time. Look forward to seeing what happens with yours. How have you liked the new CV axles?
 






I totally get what you are saying. I would like a V8 swap but I think I am gonna run my sohc and see how many miles I can get out of her this time. Look forward to seeing what happens with yours. How have you liked the new CV axles?
Partially why I'd rather not swap mine yet either, ol' girl's still pushing, may throw a CAI in and such to try and gain just a little more power for the wheels, even a little would be nice. CVs are doing well both on and offroad, haven't gone offroading too much since that last time due to being worried of getting stuck out there alone from lack of power, man I should've just gone to 31s. And weirdly I feel like my rpms have dropped, not sure if it's just not reading right like the speedo thanks to the larger tires; used to be around 2500 at 70-75 mph, now I'm closer to 2200 at those speeds?
 






The manual 4406 will fit fine in the 4dr's with the 22 gallon tank. Some have had to R&R the front mount and trim it a little.
 






Partially why I'd rather not swap mine yet either, ol' girl's still pushing, may throw a CAI in and such to try and gain just a little more power for the wheels, even a little would be nice. CVs are doing well both on and offroad, haven't gone offroading too much since that last time due to being worried of getting stuck out there alone from lack of power, man I should've just gone to 31s. And weirdly I feel like my rpms have dropped, not sure if it's just not reading right like the speedo thanks to the larger tires; used to be around 2500 at 70-75 mph, now I'm closer to 2200 at those speeds?
yep, your rpms will drop with larger tires... they make your final ratio taller, as the driveshaft/engine/tranny have to turn less to maintain the same speed, as one revolution of the tire pushes you further... i think... grimmjeeper (website) has a great tool to determine your rpms at different speeds!
 






You can figure your rpm's or any changes with easy math, for the tires, gears or TC's, or a trans swap.
 






Did you adjust the speedo to the larger tires?

The computer shifts the tranny and locks the converter primarily by speed in MPH and Throttle Position. If the speedo is not adjusted, it will not down gear as it should to keep the engine at the right rpm unless you put the pedal to the metal. It should be up-shifting a bit later. The torque converter will be locking a bit later and wont unlock as soon as it should. The unlocking later is like downshifting later and hurts performance.

I like this site for tire size calcs:
 






also, according to grimmjeeper, w/ 5r55e at 70mph with 29s/3.73 you are around 2270 rpm, but w the 32s/3.73 you are around 2060 rpm, so a 4.10 ratio would put you back at stock numbers, but because the tires are heavier, you would ideally want a 4.3 like Don said... however, i dont believe they make a 4.3 for the front, only the rear, so if you're rwd that'd work well, but for 4wd, you may be interested in the 4.56s... at the cost of some highway fuel economy, but more power off the line than the 29s/3.73 (i think)
 






I have 5:13 gears and mine is still gutless with 35" tires. 2300-2400 RPM at 65, which is its cruising speed. It's a lot for that little engine to turn.
 






Dang @BKennedy, really that well at 65 with that high of a gearing? I want to go straight to the manual 4406 but that involves the whole 5.0 swap project, which I certainly ain't ready for. Could get everything easily from the junkyard for an added price of like $5-700, but that's not including rebuilding everything to be sure. I haven't reset the speedometer, need to, but I got the jist, website said it would about 5 higher at 60, according to a view navigation apps and vehicle readers, its about 3 over what it says, not too far off.
 






also, according to grimmjeeper, w/ 5r55e at 70mph with 29s/3.73 you are around 2270 rpm, but w the 32s/3.73 you are around 2060 rpm, so a 4.10 ratio would put you back at stock numbers, but because the tires are heavier, you would ideally want a 4.3 like Don said... however, i dont believe they make a 4.3 for the front, only the rear, so if you're rwd that'd work well, but for 4wd, you may be interested in the 4.56s... at the cost of some highway fuel economy, but more power off the line than the 29s/3.73 (i think)
Problem there is, I like my highway speeds, just under half my driving is on the highway. If I can just increase my current engine power, make it 2WD, or just go with that dang engine swap, I would think the current gearing is fine, at least that's if I base it off something like the suburbans logic. 3.73s, 6" lift, on 33s with 16s, doing freaking burnouts on every takeoff. Think he has a 350 under the hood? Something like that, its bigger than the 302 for sure, but the 302 would definitely be a start for having less issue with the tires; even with the 3.73s, it would have the power and torque to not even care that they're bigger, especially if I add some power upgrades on top of the 5.0 swap. Think that's the route I'm stuck with since there ain't a lot to get out of mine without just swapping or going with a supercharger, which at that point I'd rather just swap to the 302, better in the long run.
 



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Dang @BKennedy, really that well at 65 with that high of a gearing? I want to go straight to the manual 4406 but that involves the whole 5.0 swap project, which I certainly ain't ready for. Could get everything easily from the junkyard for an added price of like $5-700, but that's not including rebuilding everything to be sure. I haven't reset the speedometer, need to, but I got the jist, website said it would about 5 higher at 60, according to a view navigation apps and vehicle readers, its about 3 over what it says, not too far off.
one thing however, is that i believe bkennedy has the ohv version of the sohc, which makes less power, and also has a different powrrband as well... and i believe he may have the chevy 700r4... but I do agree that at some point, the 5.0 may be a good bet, as its more stout than the sohc, along with more power adder options... one thing to consider also though is that you can buy an awd 5.0 already, and swap a 4406 into it,, although I do know youve put tons of work into deathrow... this may just be one of my favorite built threads to watch! best of luck with the build!!! :D
 






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