Reversion to manual 4X4

[Triton46]

Has anyone done this? My auto 4X4 stopped working in 93, started working again 6 months ago and is now not working again. With all these problems I am considering taking out the electric motor (punting it as far as I can) and putting in a manual. How hard is this and what kind of costs involved? Is it as simple as removing the electric motor and replacing it with a manual mechanism from a junker?

 

[brianb9]

Switch to manual transfer case

You have to switch out the whole transfer case as the housing is set up differently for the electric motor. I did mine and all you need to get is a used manual transfer case, the stick and linkage, a new access plate with cutout for manual stick, and a new rubber boot for the inside single for auto trans or double for the manual transmission.

Your other option is to remove the motor and clean the brushes and armature as this is often the problem and is a very inexpensive solution that the dealer will not tell you about. Check for threads on this as it has been posted several times on the sight.

 

[Triton46]

How much did it cost you to do the conversion?

I will probably try the cleaning first, but I think the manual would be more reliable in the long run. Also, did you have to change out your automatic hubs as well?

 

[brianb9]

Manual conversion

My cost was about $300.00 for the transfer case and another $50.00 for the linkage and stick. The access plate and boot were new from the dealer and were not too bad, something like $20.00 and $30.00 respectively. I had the installation done the same time as my tranny and clutch so the additional cost was minimal.

As for hubs you do not have to change them but, I did as I have had the auto ones blow up at inoppurtune times and it's not a matter of if they will go but, it's when. The Warns I got have a lifetime warranty and are pretty bulletproof plus I don't mind getting out to turn them in. They were only about $100.00 and took about an hour to install myself. Hope this helps.

Brian