Flyboycoe's AWD 5.0 to 4WD Conversion

[JIGAWHAAT]

Looking forward to hear of the final results.

 

[AMMO_HOOAH]

BTW do you have the CV style front stock d-shaft or the double cordon type? Cause if you've got the double cordon I always wondered if you could use that instead (I traded mine for an 8.8 open diff before I could try it).

 

[FlyBoyCoe]

I had the CV style. Those damn bolts take forever to get out using only a socket wrench. I've got to get pneumatics!

Here's a pic I snapped with my phone just a while ago of the shifter:

I'm still knobless, can't make up my mind what I want.

And just playing around on base this afternoon...

 

[AMMO_HOOAH]

Get one of these

 

[MountaineerGreen]

I picked up my front driveshaft this afternoon from the same place I got the first one, Denver Truck Parts (38th and Walnut for us Mile Highers). The guys there were really helpful. Normally they have a policy of "check your part before you leave, if you buy the wrong part, you now have a spare" (as the sign reads). But I explained to them what I was doing and that my driveshaft was too long. So they took me back to the warehouse and sized it up along with other F-150 front shafts. Sure enough, I found the one I needed. The clerk said "Yep, that's the 4.6 liter." I'm going to put this in bold so people can find it later:

The front driveshaft needs to come off of a 4.6L V8 F-150 or Expedition.

For the same reason that the rear shaft needs to come from a 5.4L V8. The transmissions used on those trucks are different lengths (with adapters). Therefore so are the driveshafts. The 5.4L front shaft is about 4 inches too long for the Explorer with the BW 4406 t-case. I guess all the rest of you got lucky and picked up the correct shaft. Anyway, my hybrid u-joint was already on the other shaft, and I asked if they would switch it out for me. They were too busy, so he told me to just take it. So I got my new driveshaft for free! Two for the price of one, except that one of them is essentially worthless.

I will be installing the new shaft tomorrow afternoon most likely, and will then search for some stuff to climb over in 4LO!

If anybody wants a spare driveshaft for their 5.4L F-150 or Expedition, let me know. That goes for the perfectly good Explorer AWD transfer case as well.

Thanks for the info- I'd like to know how much space your 4.6 ds has left when you install it. Meaning is there any room left in the slip joint?

 

[Turdle]

If anybody wants a spare driveshaft for their 5.4L F-150 or Expedition, let me know. That goes for the perfectly good Explorer AWD transfer case as well.

Check your PM's

 

[FlyBoyCoe]

Check your PM's

I just got back to the computer, sent her a PM about the t-case.

So unfortunately the 4.6L front drive shaft I picked up yesterday still does not fit (just barely tho). There's about 1/2 inch difference with the slip shaft all the way compressed.

The 4.6L shaft is 34 & 5/8" from the end of the u-joint to the end of the flange. There is 34" between my diff yoke and the t-case flange. The 5.4L shaft is a good 4" longer.

I'm wondering if it has something to do with my transmission. Do Eddie's have a different tranny? Because I had plenty of space between the t-case and the gas tank bracket and now the front driveshaft is too long. So for now you guys can ignore what I said about in needing to come from a 4.6L Just measure the distance before you go get a shaft.

I guess I'll just get this one cut down to size and suck up the cost. I'm tired of not being able to drive with 4 powered wheels.

 

[MountaineerGreen]

The driveshaft I had was a tight fit- it barely would wedge between the front diff and T case. After my supelfit, the diff was moved back more, and it was impossible. I had it cut down 1.5" and it fit fine.

 

[Tilt168]

loookin good bud! can't wait to come out and have a first hand look-see...sunday maybe?

 

[FlyBoyCoe]

loookin good bud! can't wait to come out and have a first hand look-see...sunday maybe?

Sure thing if you want to come on base. I will probably try to get my driveshaft cut down this week after I get the exhaust work done. I just got those wheels/tires balanced yesterday and it drives so much better. I got up to 19 mpg on the highway last night.

 

[FlyBoyCoe]

I got my driveshaft cut today and will pick it up tomorrow sometime. I'm so happy to see this project coming to a close. School has been absolutely crazy, getting ready for finals. After that it's time for MOAB '07!!

 

[FlyBoyCoe]

Also, could anybody let me know which screws hold the console lid down. I think I reassembled mine wrong cause the lid is very loose. A picture would be awesome if anybody could get one. Thanks!

 

[Turdle]

Also, could anybody let me know which screws hold the console lid down. I think I reassembled mine wrong cause the lid is very loose. A picture would be awesome if anybody could get one. Thanks!

Tell you what-
I'll take one out and get a picture right now-if you'll measure the front to rear throw distance-at the floor, of the shift lever. I don't have mine yet, and want a boot which will cover the hole--

 

[FlyBoyCoe]

Deal. I can get that to you tomorrow if that's okay? Gotta study tonight and my truck is parked over a mile away from the dorm.

 

[Turdle]

OK--then you'll just have to wait also-
































jk
this is it--3 of 'em

 

[MountaineerGreen]

I can go measure the throw- it isn't very far to my garage

 

[MountaineerGreen]

The throw is 2" or 2.5" front to back at floor level-

Keep in mind it has to come outward (sideways) from the 4hi to N to 4lo shift- probably about the same distance.

 

[Turdle]

The throw is 2" or 2.5" front to back at floor level-

Keep in mind it has to come outward (sideways) from the 4hi to N to 4lo shift- probably about the same distance.

Thanks

 

[FlyBoyCoe]

So I finally got my front driveshaft installed! 4WD is very nice, and the 4Lo came in handy while driving out of a muddy creek bed. It's usually all dried up, but after about 3 days of rain there was water flowing through it. I didn't have my camera, so I don't have pictures, but I will try to get some this week sometime. Thank you all for your advice on this project, I'm sure the investment will prove its worth at Moab later this month.

 

[V8BoatBuilder]

Glad everything worked out on your swap, a note on the front driveshaft for anyone who comes across this thread in the future:

On my original 4406 swap I used a front shaft out of a 6cyl F150. But as we all know, Ford shares parts among trucks and drivelines.