Ranger 2WD to AWD conversion - decode 6L5PAA2

[gijoecam]

More info to pass on:

"BW4405 Works like a BW1354 but also houses a transfer case clutch. This clutch , which is controlled by the generic control module (GCM), enables the vehicle to be driven in 4wd on dry pavement. It also has a dealer installed Neutral (N) position mode."

Source: The Ranger Station

Sorry, but they're wrong on just about all four points.

First, the 44-05 is NOTHING like the 13-54. About the only thing they have in common is that they both have one input and two outputs.

The 44-05 is controlled jointly by the GEM (Generic Electronic Module) and the TOD relay (which is ultimately controlled by the GEM as well).

It does not allow you to drive in 4wd on dry pavement. In 4auto, the system monitors the drivetrain speeds and varies the duty cycle to the transfer case clutch coil as necessary to prevent or control wheel slip. (think rear-wheel-drive-until-the-rear-wheels-slip)

Finally, as I mentioned before, the dealer-install kit is not available for all model years that the 44-05 was used. Certain model year vehicles cannot have it. (I know the 98 Sport was one of them) The t-case and motor are capable, but the GEM is not.

 

[BroncoRanger]

Latest updates 03/06/07

Latest updates for my enthusiastic friends:
(New photos here: http://www.geocities.com/smellylittlestinker/truck_parts.html)

The front axle halfshafts and one hub finally made it here and I bought new rotors so everything is going well. Waiting on the second hub. I still need driveshafts for the front and rear, but I may have a source on those in Louisville.

All the Ford factory service manuals are here now. I also ordered an Explorer electrical diagram to better understand the GEM. After reading the ATSG 5R55E transmission service manual cover to cover several times, I can see it is a long, slow process tearing the transmission down and reassembling it with the correct output shaft. It's a shame there is not an easier way to get at that snap ring on the output shaft. I'm tempted to have a shop do that part to save time and complexity.

I'll have to get another car on the road to drive for a few weeks while I get the conversion started. It's time to go buy a cherry picker and a few other tools. The idea of a manual cable-operated shift mechanism for the T-case is looking better every day. Perhaps after that last electrical diagram gets here I'll take the time to better understand the GEM system.

Regards,
BroncoRanger

 

[gijoecam]

Am I set on ignore here? I'm starting to wonder....

A manual cable will do nothing for the 4x4high engagement on a 44-05, only the range selection can be controlled manually.

Do I sound like a parrot?

 

[BroncoRanger]

Clutching for an answer,...

Sir, YES Sir!

Just kidding. Sorry if I neglected to expand on my workarounds fully.
Here goes,...

If I don't use a GEM module and harness from an Explorer donor, then my workaround is a dash-mounted switch (a surplus OEM foglight or rear defroster switch) mounted just above the factory-installed foglight switch to engage the front output shaft clutch for when the going gets tough. In addition, I have noticed the 4x4 mode dashboard switch is more complex than a simple selector in that it provides a variable resistance load to an input on the GEM to control the output pulses to the shift motor. My workaround was a manually-operated lever to control the shift and a switch to control F/R lockup. I need to see a clear exploded diagram of this T-case if anybody has one. Is there a differential between the F/R or only a friction clutch pack and a solenoid clutch? What would it take to increase the breakaway torque? A viscous clutch or limited slip pack would be great here.

I wanted full-time AWD and this is as close as I can get without going to a completely different drivetrain. If only there were an output shaft and extension housing for the 5R55E to adapt to the BW 44-06 AWD T-case with viscous coupling.

Regards,
BroncoRanger

 

[BigTrannyProblem]

 

[BigTrannyProblem]

1 7025 Bearing

2 7065 Output Shaft Bushing

3 7A398 Front Planet

4 7D063 Overdrive Sun Gear

5 7B066 Thrust Plate

6 7017 Input Shaft

7 7A385 Output Shaft Thrust Washer

8 7025 Bearing

9 7917 Snap Ring

10 7064 Snap Ring

11 7100 High-Low Collar

12 7061 Rear Output Shaft

13 7A098 Oil Strainer

14 7A210 Coupling Hose

15 382846 Hose Clamp

16 7A149 Pump Assy

17 7Z111 Thrust Washer

18 7177 Drive Sprocket (30T)

19 7C108 Clutch Pack Assy

20 7Z104 Insulator Washer

21 7H150 Armature

22 7917 Snap Ring

23 7E085 Wave Spring

24 7R428 Apply Cam

25 7A534 Ball

26 7G362 Cam and Coil Housing Assy

27 7045 Shaft Nut

28 7B368 Output Shaft Yoke Washer

29 7052 Oil Seal

30 7B214 Rear Output Flange

31 7A443 Bolt

32 7F293 Speed Sensor (Rear Output Shaft)

33 N620480 Hex Nut (3 Req'd)

34 7B368 Washer (3 Req'd)

35 7C207 Case Stud

36 17264 Speedometer Plate Isolator

37 7A443 Bolt, Hex-Head (M10 x 1.5 x
30.0) (17 Req'd)

38 Identification Tag
(Part of 7A195)

39 7D221 Thrust Bearing

40 7G361 Clutch Coil Assy

41 7289 Reduction Shift Fork

42 7240 Shift Rail

43 7N095 Shift Shaft

44 7Z112 Spacer

45 7W074 Torsion Spring

46 7F063 Electric Shift Cam

47 7G360 Transfer Case Shift Motor

48 N800670 Bolt (3 Req'd)

49 7K470 J-Clip

50 Connector Retainer
(Part of 7G360)

51 N802503 Bolt (Hex-Head)

52 7C207 Case Stud (4 Req'd)

53 7F293 Speed Sensor (Front Output
Shaft)

54 7A010 Case Plug

55 Identification Decal
(Part of 7005)

56 7005 Case

57 7G450 Tone Wheel (Lower)

58 7A029 Drive Chain

59 7177 Driven Sprocket (30T)

60 7064 Snap Ring

61 7L027 Oil Pan Magnet

62 7005 Case Assy

63 7061 Output Shaft and Flange (Front)

64 383976 Breather Barb

65 Spiral Pin (Part of 7005)

66 7B215 Yoke to Flange Seal

67 Dowel Pins (2 Req'd)
(Part of 7003)

68 7A153 Ring Gear

69 7064 Snap Ring

70 7917 Snap Ring

71 7025 Bearing

72 7917 Snap Ring

73 7025 Bearing

74 Spacer (Part of 7061)

75 7C430 Shift Fork Facing (2 Req'd)

76 7G450 Upper Tone Wheel

77 7288 Shifter Shaft Seal

78 7W073 Bearing Sleeve (Self Lube)

79 7025 Bearing

 

[BroncoRanger]

Thank you BigTrannyProblem! I printed this out tonight.