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Ford Explorer Community - Maintenance - Modifications - Performance Upgrades - Problem Solving - Off-Road - Street
Explorer Forum Covers the Explorer ST, Explorer Sport, Explorer Sport Trac, Lincoln Aviator, Mercury Mountaineer, Mazda Navajo, Ford Ranger, Mazda Pickups, and the Ford Aerostar
You are asking things that I'm a little hazy on. It's been almost 20 years since I even worked on 302/T5 and that was a Mustang, not a 4x4.
T-5's are strong, but unmodded I'm not sure about 400 horse strong. Depends on the torque you'll run too as to the clutch holding. I've seen built AOD's running way over 400 hp, but stock AOD I doubt it would hold.
As far as t-cases go I am not familiar. I would look at 80's full-size Broncos as some of them had the 302 + AOD + whatever tcase they used combination.
Sorry I can't help more, but that is getting a little out of my experience. Might be best to ask some of the Mustang guys. Particularly Fox body stang owners, or full-size Bronc owners, about the T-5 vs. AOD. AOD would be about 1980 thru about 91 model years, of a lot of different Ford cars and trucks. Full-size Bronco w/302 sounds like the drivetrain you're aiming for. I'd want a later AOD (like 88-91) as opposed to an older one, if I were going that route.
Advance adapters sells an adapter for AOD to BW1354
I think you would need to be careful with the power on the 1354 though, but it's a start and you could upgrade later after you grenade the 1354..
NP205 will bolt direct to a 4x4 AOD, or a BW 4406 or 4407. 4407's have a fixed rear yoke. 4406 is a slip yoke. probably not gonna find a 4407 (rare and expensive) but you can convert a 4406 to eliminate the slip yoke if you so desire. again Advance adapters.