need opinions-4wd troubles

[ahuggins6]

stock setup, 1997 A4wd 4dr with brown wire mod, $2600 in parts to get it in dependable condition two years ago. Needs lots of door switch and actuator work and some sensors and soleniods on Evap system replaced. I wish i had the 5.0 instead of the 4.0 sohc. Other than that, I'm ok with this rig, but I'd rather have a full size later model bronco that can pull a trailer and do work.

Yesterday, I was kicking about 70 on interstate when a bearing in the front diff finally gave out. It's been groaning (well, grinding really) for a while. Luckily I was only about 4 miles from home so 10 mph got me there.

I really want to put a little bigger tire on it, but really for no reason other than looks; it doesn't get in the mud very often and I'm certainly not gonna do any rock climbing. This is my cool weather DD: I run my early bronco topless anytime I can.

The chain in the Tcase needs replaced, but I hate replacing any chain without sprockets. Question 1: Do these cases do well when only the chain is replaced or should I replace the whole thing to get new sprockets and sensors? I rebuilt the case a few thousand ago just to see inside it and try to diagnose the flashing 4wd light problem. Decided not to replace the chain because it didn't seem too loose. Question 2: Has anyone changed the chain without pulling the whole case out of the vehicle?

If I put bigger tires on it, I really need a little more gear. Question 3: Do I take this opportunity to put lower gears in it (4.10 diffs from a ranger) or stay with stock stuff because it's really unnecessary to put bigger tires on it.

I'm gathering that 31's fit without lift? Correct me if I'm wrong.

I've had an idea to cut the frame out of a upullit truck and widdle on it until I can weld it up under mine, creating lowered lower control arm mounting points, and then build some heavy duty extensions for the top of the spindles. This way I'm basically building the same parts that cost over a thousand dollars for the 05 F150 I used to have just to lift it 4". And of course, the 4-5 inches lift I'd pickup would require a much bigger tire than I really want to run, and 4.10 gears wouldn't really be enough to maintain the little bit of git-up-n-go I've got right now.

But again, I don't really need it; it would just look really cool, and cost me more gas to turn those big tires.

Thoughts please.

 

[MercuryMullet]

I'd put the 4:10s and 31s-that would help the V6. Or buy a v8 and put a real transfer case in it. Mine, I have a different frame under mine. I went TTB.

 

[ahuggins6]

So if I got a 5. 0 powertrain would the interior harness have to be changed along with the engine harness?

 

[MercuryMullet]

So if I got a 5. 0 powertrain would the interior harness have to be changed along with the engine harness?

Whatever answer I give is a educated guess. I believe the the dashes are plug and play, I think you need the engine harness only. Once again i would ask someone who knows more than me.

 

[ahuggins6]

Well. Swept the shop floor this morning and pulled the Ex in. Began taking the front drive shaft out, and notices that the t-case was making some noise when I turned the shaft. Eventually slid around so I could see the back side of the case. Found a HUGE hole in the housing at the rear bearing on the front output. Now I need a new t case. And don't have that kind of money....