Transmission swap code rabbit hole

[Scotts96sploder]

I have dug through the forum, cannot find this.

I’m working on a one ton swap, starting with a 96 5.0 2wd. I can use my 4r70w if I can find the output shaft/tail house kit for 4wd, but they are sold out everywhere. I wanted to run an np205 but I can’t find an affordable one of those either. I have found that I could find a bw4406 in a 96-03 150/250, or 4407 96-98 250/350, which I believe were also 4r70w. So my question is, will the transmission out of one of those trucks bolt up to my 5.0? Im hoping to get lucky and find a trans/xfer case as a unit.
So thats where the rabbit hole starts of ford transmission codes ( mine is a PKF-AC) which I started reaseaching to see if I could find a chart for the codes in order to know what codes to look for that will swap. Dose this list exist?
My local yard only charges $100 for a trans, and $100 for an xfer case, doesn’t matter what it is, I’m kinda poor so if there is a way for me to pull this stuff that would be amazing, and if someone knows of what year, or motor(like the5.4), or specific code I’m after I would really appreciate the help.
P.S. whoever thought to make the post title a search is a Genius!

 

[410Fortune]

the 4406 will work
The 4407 is a true 3/4 ton 1 ton case
the 4r70w AND 4406 are HALF TON truck stuff

The Ford NP205 is getting harder to find for a good price, parts to fix them also getting harder to find. The NP205 is a gear driven case, works really well in a ranger/explorer, can be twin sticked and they are bomb proof. But good luck finding one AND they have no options for lower gearing.

The 4406 t case is what we use in these trucks

The 4407 is HUGE and will not fit between your frame rails

It goes something like this
the 302 and 351 used the aod/e and BW1356 t case
The 302 and 351 evolved into computers and now used the 4r70w and 4406 t case (94+?)
The 4.6 triton (96+) also got the 4r70w and 4406 t case until its last year of production which was 2014 I believe

BUT anything with the 5.4/6.8L v10 or diesel uses the larger 4r100 (E4od) and 4407 t case (3/4 ton and full ton)

So what you are doing with a 302, 4r70w and 4406 is actually a half ton conversion (F150) and this is a GREAT setup in your explorer
You want a 4406 t case
You can research the 4x4 or 4406 conversion here on EF.com
I converted my old 96 sploder to a 4406 manual t case waaaay back here is the thread

410Fortune 96 AWD Ex - goes low range

I picked up my transfer case last night. Two t cases were included in the deal, one is strictly for parts. The t case I will be using in my 96 5.0L AWD explorer is a 2001 F-150 BW 4406 manual shift :) this makes me very happy. I will no longer have full time AWD, instead I will have 2wd, 4hi...

www.explorerforum.com

There are two maybe three types of 4406 t cases. The 4406M (manual shift) the 4406E (electric shift) and the 4406E with TOD which is electric shift and has torque on demand feature. The 4406e uses the exact same shift motor as Rangers and 96-01 explorers so it is a nice swap keeping your 4x4 dash switch

 

[Scotts96sploder]

That was a lot of information, thank you!
So if I find a 96+ 150 with the 4.6, that transmission will fit? I’m asking because I was told that the bell housing changes even between explorers with the 4.0 to the 5.0, and it looks like finding a 4wd trans will be easier that converting my 2wd.

 

[CDW6212R]

The 4WD output shaft and the short 4WD tail housing shouldn't be very hard to find. You should be able to contact some sellers about it who seem to have the late 90's Explorers or F150 truck lines. Those should be the same I think. Worst case if you can't find it easily, to pay $100 for a trans there to get them, is not too bad.

Your 96 Explorer needs a speed sensor(VSS) on the tail housing of the transfer case, like what is in your 2WD tail housing. The Expeditions had the VSS in the tail housing in 1998 still, those began in 1999 to have it in the rear(ABS sensor). So selecting a transfer case is tougher for the older Fords that need the speed sensor in them.

 

[CDW6212R]

You have to use a two bolt starter for the 302 or any SBF. Finding a 302 Explorer with AWD for that trans(4R70W) shouldn't be too hard, but look for the lowest mileage, and preferably a 98+ 4R70W. The 4R was also in many late 90's V6 F150 type trucks, 4.2 V6 I think it is. Again, confirm the starter takes just two bolts, all modular Ford engines take three bolt starters.