new here, need some info

[AtroXR7]

Hi, just found this board looking for frame information.

I run a 96 Mercury Cougar. My father runs a 03 Explorer XLT 4x4 and im hooked on the traction it can get. rain, snow, whatever, that thing can hook and pull hard. So I got thinking about a 4wd conversion for my cougar since im just finishing up a rebuild on my go to work car and need something to do to the cougar. Im pushing 120k miles and bolt-ons arent doing it for me anymore. With the experience with my dad's explorer and the fact that a 02-04 is the most direct PI engine swap for an mn12, I started looking into things more. The wheelbase, front and read tread width, body width, and turning radius are all within an inch. Plus both are SLA suspensions.

So here I am doing some real research on the project. I've never really dealt with 4wd before but I understand the basics, and im not bad with welding, fabrication, and cosmetic work. Are the 02-04's full frame, unibody? anyone have extensive pictures of the frame so i can see what I have to work with before spending $? Anyone ever done a custom frame swap like this that could help me with questions along the way? Oh, and, Is the 5R55W/S the only 4wd transmission available? Id like to go with a manual but I dont know if theres any that fit a 4.6 bolt pattern plus mn12's very picky about tranny length for a floor shift.

Thanks

 

[Mbrooks420]

So your planning on swapping your unibody car onto an Explorer truck frame? Thats a serious project there There is probably a forum for things like this. It is fairly common for mud runners to use a car cab on a lifted 4x4 frames. Does the 4.6 come in the Cougars? It's a wide motor.

 

[AtroXR7]

yup, stock NPI 4.6 with a 4R70W. The V8's are pretty much shoehorned in since the car was never meant to hold an 8. 8.8 rear (swapped in some 3.73's with traction lok and an aluminum driveshaft from a 93 mark 8) Ive got the torque converter to match sitting there and and was ready to do a Jmod (cheap valve body modification procedure created by one of the ford tranny engineers.)

the original idea for the car was to be a 500hp twin t03 road car, but i have serious doubts about its traction capacity. The big question everyone is giving me is... Is that even possible? Well, I figure it'll take a few months research at least to figure that out. Ive seen people monster truck things but thats been done with everything from a beetle to a GT40. Im looking for a concealed rally height kind of. Probly very far from what you guys typically do, but ya never know where you'll find a guru.

 

[Mbrooks420]

Honestly I really don't think its possible. The Cougar body would almost have to sit on top of the truck frame, so it would have at least 7 inches ground clearance. You may be able to sink the frame into the cab, but thats some serious work, and may not even be possible.

 

[AtroXR7]

allright... very valid point. Never really considered the additional height from the frame. That would be way too much. I was only considering the 2-3 inches of additional ride hight.
That leaves me with the possibility of using the components only... I guess ill have to take a lot of measurements and see what I can do.

Oh and... one lil question... I know the difference between AWD and 4WD, but what parts are different in the two?

 

[Mbrooks420]

The t-cases themselves are a little different. The 4x4 model t-case uses an electromagnetic clutch that can be locked for 4x4 high, or clutch to give an automatic "on demand" 4x4 operation similar to electronic AWD. AWD t cases use a viscous coupling to send variable power to both axles 100% of the time, like the stock sports car AWD's.

 

[EliteConcept]

i've seen work like this done, there is a "thing" in my town that has a car body on a truck frame.....i did a double take when i saw it the first time.
not sure if what you speak of is possible but i know that i've seen something simliar done.

 

[AtroXR7]

Ok I can make this work but the exhaust will have to all come down one side... that give me more reason to do a single turbo rather than twin. I'll need a shorter driveshaft, but thats no big deal cause I have one of the longest single shafts out there now. The big problem is gonna be the front axle assembly. Im going to have to fabricate a new tubular K member that will allow the housing to sit right up near the oil pan with a mounting bracket on it to tie in the axle housing.

From there I'm pretty sure i can use the explorer half shafts and just mix, match and modify front suspension from explorer and cougar SLA parts. Ill need the explorer knuckle and may have to adjust mounts for a lower control arm. Should be able to maintain the cougar upper control arm and the tie rods are pretty similar. Hopefully there are no clearance issues with the power steering... It looks as if a front output shaft would sit just below it