Manual BW4406 second time swap

[johnsonR1]

I tried to return the shifter lever to the dealer or at least exchange it......but it was a no go. So I took my business else where. I found an online dealer that I ended up ordering from. All you need is the ford part number and they order it from the factory. Shipping was quick, it took only 2 days from the time I ordered it. So my shifter lever came in on Friday and finished the install on Saturday.
I have pics of the whole swap, I just left the camera at my parents house. If anyone is interested I will post them.
So far my MPG has jumped to about 20 going down the highway. I don't know what it is for town driving since most of mine is highway. I did notice a vibration at highway speeds but it went away once I installed the front driveshaft. Maybe front differntial? The road noise I was hearing was the gas tank bracket rubbing against the tailshaft housing. So I had to bend it out of the way when I was installing the front shaft.
Other than absolutely no traction in the rain I LOVE the BW4406, something Ford should have done from the factory.

 

[Hokie]

Other than absolutely no traction in the rain I LOVE the BW4406, something Ford should have done from the factory.

heh... when I had 4.10s and stock 30" tires I had to ease into a corner after a stop sign. I ended up facing the wrong way several times

 

[CDW6212R]

heh... when I had 4.10s and stock 30" tires I had to ease into a corner after a stop sign. I ended up facing the wrong way several times

Exactly why I bought the electric shifting BW4406. My V6 4WD Explorer does great in the rain in turns, hopefully the 4WD 302 will also.

BTW, did anyone ever measure their final drive shaft length in front? I have not bought one yet, I may lengthen my custom AWD shaft.

 

[johnsonR1]

I just went out and measured. The front shaft is from a 1999 Expedition with the 4.6L. From weld to weld it is 28 3/4 inches. On the T-case side is the flange and the front diff has the conversion U-joint. I can get a measurement on the rear if needed also.

 

[CDW6212R]

Thanks for that measurement. I gather also from Evan that he shortened one of those 1.5" for Jon, and has a combination of his own that came from two used shafts. That got him a Double Cardon joint, which should eliminate vibrations common to front shafts. My custom AWD shaft has too small of a rear flange to mate to the BW4406, and likely is a little short. But if I buy a used shaft with a D.C. joint, I can use it to make a good one. Regards,

 

[johnsonR1]

I think that I might have an extra flange that would bolt to the BW4406 if you need it. I won't be able to check until this weekend though......all my parts and stuff are up north at my parents house. Let me know.

 

[CDW6212R]

I'll see what used shafts I can find with a double cardon joint, I'll look for one with the larger flange of the BW4406. I'm headed to a yard this week for the V6 4WD parts. Thanks,

 

[MountaineerGreen]

Don, look at this thread:

http://www.explorerforum.com/forums/showthread.php?t=185232

 

[CDW6212R]

Thanks Evan, I need to find my old 93 front shaft, it had a DC joint like the one that you used. I'll check the flange pattern also.