Manual BW4406 second time swap

[johnsonR1]

Okay, so here goes my second time swapping a manual BW4406 into my Mercury Mountaineer. During my first swap I could not have completed it without the help of everyone doing the research before. My thanks go out to pioneers.

The first time around I put in the magneto style VSS from a 1999 F-150, instead of the gear driven one. I was thinking I could do the tailshaft housing and tone ring swap like 410fortune did, but have not been able to find the right parts. So I finally came across a manual T-case from a '97 f-150 with the gear driven VSS and will swapping that in this weekend. I plan on using the the shifter boot and the plastic cowling from the f-150. I am going to do a little write-up on cutting the center console so that it will fit properly and try to keep a factory look.

Also I will be taking pictures so if anybody needs any specific pictures from the swap let me know. For the cutting of the console, does anyone have any ideas? Maybe heat the console and just bend it or just cut it with die grinder?

 

[chriswells78]

A few on here have heated it up and bent it in slightly. I think that is how Hokie did his.

 

[CDW6212R]

Yes, hunt Bob's install in his Ranger. He might have a thread on the Ranger forum where he had been also. Here's his summary link, good luck.http://www.explorerforum.com/forums/showthread.php?t=167165&highlight=Ranger+V8+EATC

 

[rwenzing]

On my Ranger, I had to heat and reshape the side of the console quite a lot to make the two fit together. However, that is a little deceiving because I also moved the linkage in a bunch on the transmission and offset the engine/transmission/transfer case slightly to the right in the truck. Both of those changes together moved the t-case stick over an inch closer to the console.

On the other hand, the stick may hit the inside of the F150 shift boot and bezel if it isn't moved over. The original F150 trans tunnel (where the boot/bezel was intended to mount) is wider than a Gen2 Ex or a Ranger.

http://www.explorerforum.com/forums/showthread.php?p=1752089

 

[johnsonR1]

thanks guys for the links. Once I start I will have to check some measurements for fitments before I start cutting and melting. Since I don't have a body lift I am kind of worried about the shifter hitting.

 

[MountaineerGreen]

The shifter fits fine-even with no BL. I had to tweak mine a little because the factory knob barely touched my console, no biggie.

 

[johnsonR1]

I wasn't sure what the verdict was on the BL versus no BL. The first time I installed the 4406 I never put the lever in. Now that I have the right case I am just worried about getting everything done and doing it right.

 

[Hokie]

A few on here have heated it up and bent it in slightly. I think that is how Hokie did his.

We bent the shifter linkage lever, not the console. The first time was for perfect clearance in a stock vehicle, the 2nd time was after I added a BL 3 months later. Not that big of a problem either way. We chucked the linkage lever into a vise and slipped the jack handle over the end to get the right angle. It was a compound angle, kinda back and away if that makes sense.

 

[FlyBoyCoe]

I've got no body lift and don't have any problems with the shifter, un-modified. I still don't have a shift knob on there though. I think a sweet pistol grip style out of an 80's Camaro would look slick.

 

[Hokie]

No body lift:

EDIT: Geez, I had a ton of Cummins paraphernalia in my truck then didn't I? lol

With ~2.5" Body lift:

You can see what I mean by "back and away" when we bent the shifter. While driving, I can rest my leg against it if I want to, but it never gets in the way. I did this so I could wrap my fingers around the knob without hitting the console. Boot cut pants will sometimes pick up a little vibration from the shifter and send it up your leg. It was really weird until I figured out what was going on

 

[johnsonR1]

Alright, well the new case is in and working.........however I think I received the wrong shifter lever from ford. When in 2H there is not an issue but trying to shift into 4Lo the lever hits the seat and won't engage. The seat is all the way back, when it was out it seemed like it wasnt going to be a issue. In the morning I am going to bend and maybe cut down the shifter to fit better. As of now it is way above my center console, much higher than Hokie's. Has anybody else had to make modifications other than bending?
Also the whole f-150 bezel and boot idea has been scrapped after looking the trans tunnel and whatnot.......too much work for the little time I have. At my parents house now and have to get back to Purdue for the Iowa game. I will be back with an update in the morning.

 

[MountaineerGreen]

The shifter can be bolted on two ways- I bet if you turn it around, it will work.

 

[johnsonR1]

After looking through your conversion thread MountaineerGreen I definetly have the wrong shifter. There isn't a notch on the bottom to line up with the tab and it also has 5 bends in it instead of just one. For now, I think I am going to leave the lever out and throw it into 2H with some vise grips. I might go check some numbers at ford but may have to wait until monday. I will get some pics so you can see what I mean.

 

[Turdle]

It sucks that the shifter is so hard to find. There are so many of them, and the morons at the yards torch them out. I've been trying to get the word out to the local guys about them being worth a few $$.

 

[MountaineerGreen]

I got lucky I guess, I bought everything at a local yard for one price in one trip. They lift the shifter in the truck, knob and all, the linkage on the trans (which was fortunately still there) and they had just pulled it all recently.

 

[johnsonR1]

After checking the part numbers on the invoice from the Ford dealership, they gave/ordered me:
Upper shift lever: F81Z-7210-AB
instead of,
Upper shift lever: F65Z-7210-AB

Tomorrow I am going to go and order the right one and hopefully exchange the wrong one.

Also, I have noticed an increased cabin noise with this case installed. I don't know if this is because of the hole in the floor and I am picking up trans/road noise or what. Anybody else notice this? I would hate to have something wrong with the case.

 

[MountaineerGreen]

If your case is touching the body, it will increase road noise. My shifter bolt was touching, I could hear the "gears" in the transmission. I took care of that with a big ole pry bar. No more noise.

Any my shift rod is turned around from how Hokie has his, mine is nearer to the dash in 2 high.

 

[FlyBoyCoe]

Hokie bent his rod on purpose.

 

[Hokie]

Any my shift rod is turned around from how Hokie has his, mine is nearer to the dash in 2 high.

Huh... didn't know you could do that

Hokie bent his rod on purpose.

heh, yeah... chicks dig it that way

 

[MountaineerGreen]

Here is how mine is: