Kyle's 4406 T-Case swap!

[Turdle]

Some prefer a gasket, but I just used mega copper sealant. I think it will be fine.

 

[turboexplorer]

K the T Case is out

 

[turboexplorer]

The 4406 is IN!!!!!! Not fully finished but it's good for tonight. I have everything in but the interior back together and the tank and T- Case Guards. I took it around the block and ran good no vibration or anything. Then drove it home. (used parents garage I don't have one in my town home) And it ran good. Happy so far and that thing is crazy heavy to lift in there. The only thing with it is that I have a slite whine. And it goes with speed. I meant to put some ATF on the front seal of the T Case and then forgot until after it was all sealed and in. It may be that that seal is a little dry, if thats the case I hope it goes away after its driven a little and oil gets flung over it. And it can spin the tires really easy

O and the OEM shaft that I pulled out of it. ( the second new one in 2,000 miles) It is bad way bad its hard to really even move that CV. O well the AWD is gone and Six states for the warranty is going to build my front driveline for it!

 

[turboexplorer]

Correction it's a squeal not a whine! Oops

 

[Turdle]

drive shaft rubbing on gas tank?

 

[turboexplorer]

No, I have plenty of clearance I believe. It doesn't feel like a mechanical thing like the t case or shaft or anything like that. It is more of a high pitch squeal, really similar to when the seal that is on the half shafts, that seal it to the steering knuckle, went out. Will lift the rear this morning and spin it and see where it is coming from. Didn't notice it first time I spun it started just a block or two down the road.

 

[turboexplorer]

Alright interior is almost all back in other than bolting in the Passenger seat. I put it in the air and spun it up and I found the squeal. It's coming from the rear T-Case seal. What had happened is the seal reaches the pain that I painted the shaft with and that paint is making it squeal. I am going to my girlfriends Volleyball game if I don't then I am dead. So will come back pull the shaft and rub off the paint so there is plenty of clean shaft before the seal put it back in and should be good to go!

BTW it spins the rears really easy

 

[turboexplorer]

The interior as all back together and the shaft squeal is fixed. The 4406 Swap is DONE! I drove it twenty miles some freeway and around town it feels good no vibrations or noises. Now will see what the MPG does. I'm really hoping for a little bit better. All I have left is to find the linkage and then that will go in on another Saturday. The swap was a successes and went good thanks to all of your posts and info! I'll post a few pics of it later. Thank You everyone for your help! Much appreciated

 

[nssj2]

And another v8 drive train is finally done right lol. enjoy the new mod

 

[CDW6212R]

Well done, nice.

 

[turboexplorer]

The squeal is back. It only does it when it has sat for a little while then it will squeal drive a few miles and its gone. Only does it under 30 MPH. Think its that same rear T-Case seal. Will lift it and look at it again, haha. O the joys of changing things on the trucks Way happy with performance though!

 

[Turdle]

It is like having a new truck huh?

 

[turboexplorer]

Here is a few pics of my swap.

First one is how I got to that bolt right next to the cats it worked really well.
Shallow socket, 3" extension, swivel, then extensions out the top to where you can get to the ratchet. This picture is from the drivers side to the left of the pic is where the front of the truck is.

This one is of the AWD case. See all the clearance with this case? Also see the grease ring above the left side of the case where the front shaft is. You can see where that shaft took a crap and lost all its grease.

These two are of how the bracket looked after I beat it with a sledge! I got it the first time didn't have to bend it after I did this. Also no big deal to those doing this you can get the T-Case in and then slide this bracket on and off as need to clear the case. Really easy if you drop the tank is well worth your time to do so. I left my filler neck attached and slid the tank back a little so it could sit on the rear diff so the weight isn't on the hoses.
Hope this helps a little.

 

[turboexplorer]

It is like having a new truck I like it. I feel that is will get a little better mileage.
Interesting to take it to the track and see if it made any difference as far as my time is concerned.

 

[Turdle]

Yes, do this! I want to know. I really wish I had made a before run.

 

[turboexplorer]

I wish that I could have made a dyno run before to the the few AWD dyno's are a lot more expensive to make pulls on. Was just curious about the actual power to the ground. But the Vegas track where I race has runs all the way until Dec 12th so I will go down and run it for sure this year. Was a 18 flat before will all my audio so am going to leave it in to have same weight and things and see what was gained as far as my ET.

 

[turboexplorer]

Hahaha, this gives you an idea on the size difference between these two Cases. Like everyone that has done this it fits nicely right at home!

These two are of where I clearanced the body for the case. That corner on the floor pan that I painted with a good black paint (all I had just like jtsmith) to make sure no rust and also if you look to the left I had to bent that heat shield between the exhaust and the body a little its a light medal that bends real easy.

 

[turboexplorer]

Cleaned really well and put a thin layer of sealant to the case and to the trans.

Back view after the case is in! You can see the clearance difference with this case. Sorry this pic you can't see it real well but there is a lot less room but plenty for what you need. Also I cut off those two top nubs on the T-Case it makes for more room!

Front view after the case is in!

 

[turboexplorer]

These are pics of the clearance of my drive shaft. You can see where I cut the plastic away and dented the tank a little. First pic it not dented other three is dented. No more than 1/2" really. Last pic you can see it the best. I have 3/4" of clearance.

 

[turboexplorer]

Here is the clearance between the tank bracket and the case.

Tank and the case

General fit. See how good it looks in there!!!!!!!!!