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My project is home!!

My project is home!! (2x4 to 4x4 swap)

Well I drove (trailered) my project home at about 5am sat. morning after a 21 hour drive to NJ and back to pick it up. The trip should have only taken about 14 but with traffic and all it took a whole lot longer. Anyway, it is my donor truck for my 4wd swap. It is a 1991 XLT with 3.55 gears, warn man. hubs, nice interior... without saying the truck is a whole lot nicer than my XL. I would love to just keep this one and build it up, but do to the body damage, tranny stuck in reverse, and my XL's engine haveing less then 40K on it I am going to make the swap. The idea is to pull out:
Front and rear axles and driveshafts
Swap tranny output shaft
Front suspension, brakes
Transfer case
Shift computer
front seats
dash
misc other parts that are broken on mine

I pulled out the interior today and then pullout the shift computer, then pulled the tcase skid plate, and front and rear driveshafts. Tommorow after work I'll pull the tcase and tranny. Then I'll take the tranny up to work and me and another guy there are gona pull the output shaft out since my knowledge of the tranny isn't enough to do that. I should have pics up tomorrow, along with another progress report. I will aslo be parting out the rest of the truck, so you can email me or wait until i post in the for sale forum.

Chris
 



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Haha naw it wasn't too bad. The major problem i incountered were those rivits. I got the front drive shaft in and re tightened everything today at work, but the 4wd still isn't engaging. The lights on the switch light up but the little yellow light doesn't light when i push the putton. I also have a grinding noise while in reverse comming from the front right. I think that might be the wheel bearing as i noticed some play in it. Any ideas as to what could be the problem with the 4wd?

Thanks
Chris
 



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Are you hearing clicks from the shift computer? If not that could be part of it. did you test the 4x4 parts on the parts truck before hand. If you hear the clicks I would think it would be the shift motor on the T-case.
 






Nope no clicks; push the button and nothing. The guys at the tranny shop said the tcase was in good shape. I just played with the wiring a bit and it was all conected well. The only other thing I can think of as far as wiring goes is the shift computer ground. Maybe becuase there is paint (i think) behind the connection it itsn't getting a good ground.
 












That is what I am thinking, because as Kris said if it was a bad tcase there is usually a clicking nose heard from the computer, but I hear nothing. So I will try that and see what happens. But as for now it is time ot hit the hay and get ready for a long day tomorrow.

Chris
 






I was thinking about it and I though of something. Did you put a Fuse in the Fuse box under the hood for the Elec Shift. That might be why you have no power.
 






Hmmm... that never even crossed my mind. Good thing you said that because I was getting mad. I re did the ground and pulled the plugs to push the white button and the light never lit up. So I will run outside real quick and try that.

Thanks
Chris
 






Yep that would be the problem. It now shifts into 4x4 great, but doesn;t seem to go into low range. I am gona search around and see what some of the possible reasons could be for that. Another thing that I noticed is the the fuse for "Rear Dif" wasn;t in my truck, but in the donor truck. I put it in mine, but am not sure what it does. Is this for a limited slip diff? I have to give a big thanks to you Kris, becuase you have helped me the whole way through, along with putting this wack ass idea in my head.

Thanks
Chris
 






your trannsmission has to be in Neutral to shift to Low range

Kris
 






Originally posted by Isles4evr
Another thing that I noticed is the the fuse for "Rear Dif" wasn;t in my truck, but in the donor truck.


Rear window defrost maybe...
 






Yeah I had it in neutral and foot on the brakes. I am going to try the tricks I read on the board to see if I can get it to shift into it. And the deforost might just be it since I don't have it and the donor truck does so that could be it.

Thanks again
Chris
 






Well after getting very frustrated with my auto tcase shift motor I went out and bought a manual tcase. Gona order the shift linkages and boot from ford and install when i get back from vacation next week. One question... he two wires that come out of the case, can i just splice them into the current harness that hangs down so that I cna have the lights working on m truck?

Thanks
Chris
 






Chris,

I never figured out a way to get the Lights to work in my Navajo.
 






hahah... what about if you ran the wires into the harness for the lights themselfs?
 






this is a good question for a guy with wiring diagrams from helms for a '91 explorer....... :p :D :redexp:
 






Yeah i would think that would help out quite a bit. I am going to install the case when i get back next week and then play around with the wiring a bit. My boot and linkages should be in by then from ford (i hope).

Chris
 






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