tcase swap

[Douce_8]

has any one swapped a 94 explorer transfer case into a 95?If so what has to be done to make it work?Both tcases are electric and look to be quite similar.I dont know it it matters but my explorer says it was built in 01/95.

 

[Douce_8]

has anyone swapped a manual shift transfer case from an older explorer or ranger into a 95?If so what is required to make it work ?anyone have any info? thanks

 

[Douce_8]

if the chain is broke inside of the transfer will you still have rear wheel drive?

 

[Mutineer]

if the chain is broke inside of the transfer will you still have rear wheel drive?

Yes, the rear is not driven by the chain.

does the front driveshaft spin freely when it's in 4WD?

 

[Douce_8]

yes it seems to spin freely

 

[Mutineer]

yes it seems to spin freely

OUCH...

Seems to me either the shifter mechanism (in or outside) is not working or the chain is busted... Any Noise from inside?

 

[Douce_8]

when you engage the 4low you can hear what sounds like a grinding clunk which sounds like it trying to engage something

 

[Douce_8]

but no noise while driving and it does engage a low gear in 4low

 

[Mutineer]

but no noise while driving and it does engage a low gear in 4low

OK so were not talking a broken chain but rather a bad/broken of the following:

Synchronizer/shifter fork
Shifter rod (that the fork rides on)
4 High gear
and a few others not yet mentioned...


either way you need to bust that t-case open and look for fragmented parts....

OOOF...

If I were you Id look around the Junkyards locally and see if you can latch onto one used for cheap. Prolly cheaper than fixing that one...thats what I did when mine lost 4 HI in my 92 Ranger... got the T-case for 200 and it would cost 350 to fix the old one...

 

[Douce_8]

thats what im trying to do but i cant find any of the same transfer case which is why i was trying to find out anyothers that could be made to work

 

[IZwack]

OK so were not talking a broken chain but rather a bad/broken of the following:

Synchronizer/shifter fork

The transfer case is not synchronized -- the wheels touching the ground is what synchronizes the two outputs. And there is nothing synchronizing the LO range engagement, this is why the vehicle must be stopped and in Neutral in order to engage LO range.

either way you need to bust that t-case open and look for fragmented parts....

OOOF...

If I were you Id look around the Junkyards locally and see if you can latch onto one used for cheap. Prolly cheaper than fixing that one...thats what I did when mine lost 4 HI in my 92 Ranger... got the T-case for 200 and it would cost 350 to fix the old one...

Yes this is one of the most cost effective route. Or you can go with a manual transfer case -- same model as yours, the Borg Warner 1354, but its a manually shifted unit as opposed to an electronic motor doing the shifting. Try looking at craigslist, or maybe car-part.com .

EDIT -- I'm wrong, you have a Borg Warner 4405, I thought you had a 1st gen Explorer. But no matter, the 1354 manual will stoll bolt right up.

 

[Douce_8]

what type of vehicle can you get a manual shift 1354 transfer case out of and what years?thanks again

 

[IZwack]

Pretty much Explorers all the way to I think 2001. 2002 was the beginning of the 3rd gen and I'm not sure these ever came with a manual transfer case (probably wouldnt bolt up to your transmission anyway).

If you need more info on electronic to manual t-case swap, search for "1354" -- you'll get a boat load of threads on it.

 

[Douce_8]

so anything out of an explorer from 91-01 with a manual transfer case should be the same?So this should work even though i have an automatic transmission,and have the sensors and plugs for the electric shift transfer case?

 

[IZwack]

Yep yep -- but read up on it cauz there are some other aspects of it like:

1) the shifter which will interfere with your center console so drop the console or go with a shorty style
2) the 4wd lights on the dash will blink but you can reconnect the sensors to fool it, or other methods
4) your front axle is vacuum actuated (called the "CAD" or central axle disconnect), but theres an easy way to manually operate this (with an electronically actuated vacuum valve feeding off of the engine's intake manifold vacuum i believe).

EDIT - oh and I was wrong on reply #11. I thought you had a 1st gen but now I see you have a 2nd gen. You have a Borg Warner 4405, not a 1354. But doesnt matter, the 1354 manual will still work for you.

 

[Douce_8]

im probably going to feel stupid for asking this but what do you mean when you say
"the shifter which will interfere with your center console so drop the console or go with a shorty style" and im jsut curious if you know where a more detailed writeup is about the swap im searching through the forums looking and not really finding and incredibly deatailed writeup.Also i have bw 1350 transfer case that is manual shift out of an 85 ranger will this work ?Sorry for all the questions

 

[Douce_8]

also if i did swap in the 1354 would my original front driveshaft work?

 

[IZwack]

Well I'm assuming that you have this center console that goes from between the two front seats up to the dash.
The manual transafer case is shifted pretty much like a manual transmission -- which means it has a shifter that comes up to almost knee level.

This is an image from Nick26:

Nick's Explorer has a manual transmission so ignore the shifter on the right. But the shifter on the left is the shifter for the transfer case.

also if i did swap in the 1354 would my original front driveshaft work?

Good question, I forgot to mention that. I believe it will because I think you still have U-joints on the transfer case end of the front driveshaft. But if not, you'll also need the front driveshaft from a 91-94 Explorer, doesnt matter if the donor vehicle has an electronically shifted transfer case or manual, all 91-94 Explorer has a U-joint on the transfer case end of the front driveshaft.

 

[Douce_8]

My center console doesnt go all the way up to the dash it just has the arm rest with two cupholder ahead of each other and carpeted area ahead of that.Im going to try to find a picture.So just to clarify if i can find a manual shift 1354 tcase should be able to bolt in place of the other one,use my orginal driveshafts,and just have to make a whole through the floor for the shifter to go through.And for the front CAD could i just leave my electrical for the old tcase hooked up and use the switch on my dash to lock that before i shift my tcase or is there a better way of doing it?thanks again for all the info your being extremely helpful

 

[Douce_8]

here is picture of the same kind of console thats in my truckhttp://alecto.bittwiddlers.com/vehicles/navajo/navajo_cupholder_1.jpg