First Post need help awd to 4406 swap

[mycobrars]

This is my first post, but I been here long time gleaning info.
I just picked up a 97 explorer awd with a bad transfercase.
I read v-8boatbuilders thread, all I can say is WOW. I
want 4x4 too, so I have gathered most of the parts. I
don't have the bezel or relay's yet. But my question is where
does the 4x4 switch plug into? I found the harness for the
other 2 relays and the transfercase harness under the seat.
What I'm I missing?

 

[BrooklynBay]

Welcome to this forum! Do you have the color codes of the wires going to the switch? You could trace the wires to find where the switch plugs into.

 

[Turdle]

Are you totally against having a manual transfer case? It would make the whole thing easier.

 

[mycobrars]

I pick up my bezel, relays and transfercase harness at the junk
yard. It looks like I spoke too soon on needing help,
what I needed was some sleep, working to many hours.
The connector for the 4x4 switch was right in front
of face, it pluged in to a dummy connector in the original
bezel, I guess I thought it was one the other switches.
Thanks for help.

 

[CDW6212R]

So you have the module for all three needed, the GEM, 4WD and TOD? They all plug in behind the radio. Did you find a BW4406 with a speed sensor in the back half of it, did your AWD case have the speed sensor in it?

BTW Jon, can you check around for me for a TOD BW4406 TC? I still haven't found better than a 89k unit. Regards,

 

[mycobrars]

I picked up all 3 parts and they all plugged in behind the radio.
No problem. The transfercase I got was missing the 2 speed
sensors and motor. But it did have the speedo gear driven sensor.
I'll get the other parts when I put the transfercase in. I want
to measure, what length the driveshaft will be first, so when
get the driveshaft I'll know I'm bring home the right one.
For the front driveshaft I'm thinking about having one I have
laying around modified. It's a front shaft from a 92 explorer,
it has a cv joint style on one end. v-8boatbuilder said he had
a vibration on his, I don't what one on mine. I'm not sure if
he has a lift on his or not. I'd get the f150 shaft if I knew for
sure it would work. But it may be cheaper to just modify my
shaft. I got a good deal on my transfercase (58K miles $250) thats
why I bought it. In my area average price is $500 with 115K plus miles.

 

[mycobrars]

CDW6212R I'm not sure if this question was directed at me

"BTW Jon, can you check around for me for a TOD BW4406 TC? I still haven't found better than a 89k unit."

I found mine at this web site www.car-part.com:)

 

[CDW6212R]

Yes thanks, Jon had mentioned checking a couple of places local to him.

The front shaft from those Expedition/F150, etc. trucks do work for length. I think that they have double cardon joints, those are the key for the least vibration. Ford went to the CV joint because it is smoother yet, but wow they are expensive to replace.

I'll bolt in a used shaft for now, and have another built later when everything else is finalized.

It's good that you have a TC with the matching speed sensor, and low mileage. Those units are like all TC's, very high as rebuilt units. Regards,

 

[mycobrars]

Well I dropped the factory gas down and installed the 4406,
I swear I had it up in 10 minutes. No problems with clearance.
thanks to the 2inch body lift. I'll hit the junk yard tomorrow for the
driveshafts and tc motor. I found out the sport gas is about
10" shorter than the 4dr. So far looking at the angle of front
flange on the transfercase, I need a driveshaft with double cardon joints
I hope the f150/expeditons have one. The one driveshaft I have
laying around needs to be longer. I might just see how much
to modify mine. I hope to take for drive this weekend.

 

[MountaineerGreen]

The driveshafts will bolt in with no problems. Check these threads of mine:

Manual T Case Swap Thread, with Driveshaft Info-
http://www.explorerforum.com/forums/showthread.php?t=166726
Double cardan driveshaft for the swap- (not necessary unless lifted, IMO)
http://www.explorerforum.com/forums/showthread.php?t=185232

 

[mycobrars]

I checked out the pic of the 2 driveshafts 5.4/4.6
I can't tell from the pic does it have double cardon joint
on the end. I remember a couple years ago I lifted my
88 bronco ii I had to go with double cardon joint because
of vibration at 40mph. If memory serves me right, driveshaft
angles need do be within .7degrees on each end. Do you
have any problems with your shift for yourself 4x4?
Looks likes a factory install, great job

 

[MountaineerGreen]

No, none of the "standard" conversions used or needed a double cardan driveshaft. I needed one due to a growling noise due to my driveshaft angles because of my 4" Superlift, the DC fixed mine. You will be perfectly fine with a single joint. If you must have one, I have a 96 DC stock driveshaft. You would have to change the transfer case end to a flange, but it can be done.

The manual case is the only way to go, IMO, I've never had any trouble shifting it, and the wiring involved was dead easy.

I now can't imagine having it any other way, its second nature to reach down and pull it back into 4x4.