Transfer Case compatibility question

[sn8kbit]

I have a 96 sport with manual transmission, 4 wheel drive.

The transmission just locked up in 4th (knew it was coming) and I have a rebuilt replacement on the way. While there, I'll be installing a new clutch assembly, slave cylinder, ect.

Prior to the tranny pooping out on me, the transfer case was fairly noisy (I'm assuming chain). Obviously, it's the 1354 unit electric shift, similar to just about all except AWD, 91 and up. Are there differences between 1st gen t-cases and mine? I've found replacements (used, warranty) ranging between 40-129 dollars. Some from Rangers (99) and some from first gen Ex's. Shift motor in mine is fine (knock on wood) so other than maybe a wiring plug difference, are these t-cases able to swap out? I could rebuild it, but I'm looking to assemble it straight out, and simply swap new in for old.

Searched for quite a bit, did't see anything regarding this.

Thanks,
Steve

 

[tenikiwon]

I put a t-case from a 95 in my 97, just needed to get a front driveshaft from a 95 and shorten it.

I'm almost positive you can swap any of the 95+ t-cases with minimal to no problems.

 

[sn8kbit]

Thanks for the reply, made me make a few phone calls.

Found that I actually have a BW4405, not 1354 as I thought. While I know that the 1354 will bolt up, other than shortening a 95 driveshaft, I wonder what the difference is? I take it the rear driveshaft fit fine? Since I don't "wheel" often, I'm considering going ahead and picking this up, and doing the shaft at a later convenience.

This is eating into the Cobra budget, an' I ain't a-happy 'bout it....

 

[sn8kbit]

I'm going to go ahead and swap it (for those concerned). After a bit more research on other boards, the 98 and up Ranger, and the 96 and up Explorer share similar front driveshafts, as far as connecting to the transfer case is concerned (also most likely why tenikiwon had to use a 95 driveshaft).

Once everything arrives, I'm going to do pics, and post it here. Besides, with a body lift going in at the same time, I really need to get a pic of the 'sploder.

S

 

[tenikiwon]

To bring this up. I don't like the electric 4WD. Granted I bought a rebuild one, but it's still clicking and slipping. So I figure it's time to go manual.

Does anyone know what twin stick transfer cases will work on a Gen 2. Currently I have the 5-speed auto tranny, but plan to go manual with that as well.

 

[Doug]

The cases of the 4405 and 1354 are identical, the only differences are the internals. A 1354 will bolt up to your transmission no problem. I heard of one guy running a 1354e in a 2nd gen but last I heard it wasnt going to well, transmission issues or something. Anyway you can bolt up a 1354 manual shift no problem. Imho this a huge improvent over the electric shift which generally can generate alot of problems. The only twin stick t-case that will fit an explorer would be an atlas II

 

[glfredrick]

To bring this up. I don't like the electric 4WD. Granted I bought a rebuild one, but it's still clicking and slipping. So I figure it's time to go manual.

There is absouletly no difference between the manual inernals and the electric internals. The only difference is the back half of the case and the mehanism that shifts the t-case. You can even swap on the manual rear cover and it will fit right on.

If you are having slipping and clicking issues, I would start by changing the oil - I found that when mine did that it was full of water. (And I mean FULL).

After that, if your electric shift works - just rebuild the case - no strength gained from the swap.

BTW, I am working on a manual conversion of an electric case becasue my electrical system has failed. I tried several different motors and a new switch, so I think it may be the controller module. I am making a crank system that will enter the cab of the truck to simply dial in the range I want.

 

[tenikiwon]

Manual 1354 vs Electric
The main reason I would like a twin shift is I currently have the 2WD mod and I like having 2LO and the ability to put in a quick lock vs a selectable locker in the front.

Changing Fluid
This was mentioned to me as well in fact the person I spoke with suggested to put in some friction modifyer because he figured that the heat was causing the oil/water mixture to heat, causing the slipping.

Thanks for the reminder, I'll have to try this and see how it goes on labor day.