transfer case module out again! convert to manual?

[beakman]

hello everyone...

This is an 2002 XLT V6, by the way. Finally got around to joining. Found the forum the FIRST time the 4x4 shift module went out. Ordered online, saved some bucks, put it in, presto! Fixed.

Now it appears to be out AGAIN. But I have another symptom: I knew the module has been out again for a while, but having had no bad weather (and a spare jeep around when it IS bad), I just haven't fooled with it. Well, in the fall, I came out one morning to a truck that wouldn't move, as if the t-case was in neutral. I slid under and sure enough, the shift motor had moseyed around enough that it was in the neutral position. I unplugged it, removed it, applied power while NOT installed, it returned to the normal HI position, I put it back on the t-case and rotated it around until the holes lined up, bolted her back in, and she drove just fine.

Well, it's happened again. I know the above fix will do it, but I don't want to keep doing this. So here's my question: is the shift motor going bad, which killed the shift module? Or did the dead shift module allow the shift motor to ease its way out of position?

And actually, I have another question. Is there any way to just convert the damn thing to manual and get rid of the problem altogether? There are plenty of slick cable-shifters in the jeep aftermarket, so fitting a shifter in the interior is no problem, and I can fab up a linkage if need be. But I'm an old-school manual t-case guy, so I don't know what else would need to be dealt with for it to work. I mean, I know a manual shifter put onto the original t-case would only shift it between hi and low. I believe there's an electrically engaged clutch that sends power to the front, right? So I'd probably have to switch out the entire t-case, right?

thanks in advance, everybody.

 

[macknos94]

I'm looking at doing a manual t case swap also. I'm still researching an what t case will bolt up. Another thing you can look at is swapping to the awd t case

 

[Limited02]

Your guys only luck of "bolting" up a manual transfer case will be to swap in the auto tranny and manual t-case from an F150. But I believe the F150's only have 4 gears as opposed to our 5. Now I am wondering if newer(99-04) F150's even had a manual t-case? But I could be off base here and if so, ignore me

 

[macknos94]

I believe most. Were electrically controlled in the f150 but the manual tranny had a manual t case but I could be wrong

 

[Glen4X4]

Beakman has the V6 version, if he could take off his t-case and do measurements of where it bolts to the transmission then someone here that has a 1354 or 4405 laying around could do measurements to see if they are like wise because if its like either then he could use a BW1354 manual t-case. As for your V8 guys I think the work truck version of the F-150 still had the option manual transfer case and maybe lucky enough that they use identical bolt pattern.

 

[Limited02]

That's where I'm stumped too. After rereading my post I caught an error, I meant to say 97-04 F150's. I can see a manual t-case in a bare bones no optioned work truck with the 4.6/auto.

Now other than the computer going bad, why do you guys want a manual t-case so bad? We currently have a member running near mid-12's in the 1/4 with the AWD transfercase in his turbo'd 3rd gen Mounty. I haven't heard of anyone breaking them(no ones really tried I guess?) so before spending all the money to switch electronics and cut your floorboards, plus give yourself more headaches, work with what you have and go from there?

 

[Glen4X4]

Well with a manual t-case you can have your mind at ease in knowing that its more than likely going to work everytime you pull the shifter back to 4wd unlike the electronic type t-case where it could suddenly quit at anytime or with the awd with the manual you can have a normal 4X4 type transfer case and still have dependability at mind.

 

[Limited02]

I guess it depends on how often you use it? When I bought my Ex 4 years ago, the 4x4 module was bad and ever since then(4 years) it's worked without trouble. Some people like the OP have worse luck.

If this is also for a weekend warrior, then I have no problem cutting up the center console and adding a manual t-case. But for a daily driver, it's just not worth the cost to do such a thing. But hopefully we'll find a solution and someone will be the first to do this swap

 

[macknos94]

I just don't thing the awd will be worth it after my sas. That and awd with a locked rear and e locker up front would kind ruin it. I was gonna look into the manual swap also but that's kinda outta the price range sas first bullet proof tranny and t case will be next