Help: Will transfer case from 96 4.0 work in 97 4.0?

[talltorontoguy]

total newb here. I've searched but cannot find a clear answer to my dilemma.

I have a 97 4.0 control trac with the electronic 4wd control on dash. Transfer case is shot and needs to be replaced - the case is cracked and guts broken.

I have a line on a rebuilt unit from a 96 4.0, also with electronic 4wd control on dash. I haven't seen the vehicle / case personally as it is about 1 hour from my location and want to make sure it will work before I go get it.

The only description of the 4wd system on the 1996 is that the electronic control on the dash reads 2wd, 4x4, and auto.

My 97 has an electronic control that reads auto, 4x4 high, 4x4 low. (different than the 1996)

The seller is saying that the unit will work but would require that I do two things:

1. swap the shift motor from the 97 to the 96
2. swap the ds flange from the 96 to the 97 to allow it to bolt up.

Can anyone confirm this to be the case?

If it isn't, what are my bolt in alternatives? 1997 only?

 

[talltorontoguy]

I've also just discovered that there is a 98/97 hybrid that can be done, involving swapping 1/2 the casing from the 97 unit onto the 98 unit. This is because the speed sensor in the 97 is located on the transfer case, and in the later years it is located in the rear of the vehicle.

If the 96 won't fit, how hard is making this hybrid?

 

[JDraper]

The '96 setup is significantly different than the '97. I'd suggest finding a 97-99 xfer case for the truck. In '96 the Explorers had 2WD, Auto, 4Hi, 4Lo. In 97 and up, they had Auto, 4Hi, 4Lo, but no 2WD setting. I would bet that you would have to change the electronic module too.