you need to dent your gas tank trust me, when you get the truck off road, flexy, wear in the new t case setup/etc it will rub more and more
I removed the rear d shaft, used a BFH and block of wood and made a nice round dent in the side of the tank... it clears in all situations now... took all of 30 minutes to do
Mine did not rub when I first installed the 4406, it started to rub all the time a week or so later, I suspect the trans mount allows a bit of movement and "settling"
I did not find an aftermarket trans mount for our V8 trucks, I am using the lowest mileage mount I had in my collection... it lasted about a day before it went completely flat. It allows my engine to move around alot more now thats its worn out.. so I suspect my engine mounts are toast too...
I plan to make something work this summer... I HATE the metal glued to rubber Ford factory mounts.
I have no secondary cats on my Ex so I couldnt say if there was a clerance issue there, only issue I had was the gas tank.
Also when shifting the 4406 from 4H to 4L I have to have my truck in N, not park
I can reach down and shift from 2H to 4h anytime I want at any speed (never tried over 45 mph though)
Getting the 4406 into low range is a bit of work, you really have to push the shifter far left and pull back hard in a jerking motion, otherwise it will sit between 4h and 4 low..
I got STUCK yesterday... oh man I was getting firewood for my parents (firewood is 300yards from house, been snowed in all winter until now) I didnt quite make it through the last snow drift.. I was stuck for 2 hours, I dug some SERIOUS holes in the mud...
The low range KICKS BUTT in this truck, I aired down the tires to 10 psi and still didnt get out after trying to get out for 2 hours I had to have my fiance Julee come pull me out with her FJ...
4406 rules! i want to put this same t case in my BII, but now thats working backwards (trans converted to use BW1354 t case)