With apologies to 99ex22.
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My truck is my daily driver. It is the only "all weather" vehicle I own at the moment. (I really need to do something about that, kinda tough to pick up big parts on a motorcycle)
I went with the 4406 T/case because my AWD case was junk,and had been for months. It was making all sorts of weird noises (my fave was at low speed it sounded like it was laughing).
After checking the local junkyard pricing on parts, it actually cost me $10 to make the swap. (AWD case cost $165, my Tcase and driveshafts cost me $175)
Now, for you, you may have more difficulty making the swap. The reason being that for your year AWD Explorer, the speed sensor is in the transfercase. You not only need that for your speedometer, but also for your computer to determine when to shift the transmission.
It can be and has been done by a few members on this forum.
Check these threads if you are serious. Required reading for your year explorer:
410Fortune 96AWD to BW4406 thread
VSS info you will need for the 4406
'97 V8's swap thread
There has to be more, but those should give you a decent foundation of knowledge to build upon.
Next you will need to read:
this thread by Mountaineergreen. It is basically a step by step How-to with a shopping list and part numbers.
Read all of those and 99.99% of your questions will be answered. After you have all this knowledge in your head, and if you have the tools, cash and time, you can't beat this mod.
More power to the rear wheels when in 2WD, a little better fuel economy and having 4LO to creep with.
Recommend using a forum vendor for your Ford parts by the name of Tousley Ford. Their prices can not be beat.
(
Their Q&A thread) (
Their website) (or call them @1-800-328-9552 and mention the Explorer forum discount)
My local dealer wanted more for the lower shifter (bolts onto the tranny - $130) than Tousley wanted for the same part plus the linkage arm (from that part to the transfercase) AND the second day shipping! (by the way, I did not even mention the discount. Guess I could have saved even more!)
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