Yet another T-Cases to mount to the V8 Thread

[Nitrous SSC]

how could you make it work if it puts the T-case to the gas tank?

 

[CougarX]

You can make anything work with enough time, money and inginuity....

 

[Joey P]

That's right cougar. You can make anything work. I am betting you would have to "redesign" the gas tank to make it work. I think the T-case would only be into the front of the gas tank, not in the middle anywhere. I dunno though. Someone try it and let us know.

 

[Nitrous SSC]

I ain't no monster garage I can just bolt in stuff and unbolt stuff

 

[Fusion213]

http://www.pirate4x4.com/forum/showthread.php?t=270273
He has some free cases, maybe if someone is nearby, they can pick them up to take the inputs from them.

 

[V8BoatBuilder]

At a 4wd truck show and jamboree this weekend I had the chance to crawl underneith many lifted trucks sporting the t-cases were looking at. Oh man... they're huge!

I'm also not really ready to loose AWD, and would love 2low. For me, either the V6 explorer's BW4405 +AA combo or the expedition's BW4406 are going to be my goal.

I think the biggest thing for the expedition case is the rear slip-shaft tailhousing, as i think I have solved the clocking issue for the front driveshaft.

TMSOKO, i assume the 4406's controls (shift motor and clutch) are very similiar to the 4405, so I could use a V6 explorer's GEM and relays??

More to follow....

 

[tmsoko]

From what I remember, there was no issue with the fron drive shaft - this was the only t-case aside from Atlas that I have found to bolt right up and not have an issue with the torsion bars.

The electronics are identical. You may need to repin the connector or use the connector from the 4405, but the same circuits are all there.

The biggest problem is the damned slip yoke at the rear. Some day, I will pull the slip yoke housing off to see if we could have a custom flange yoke adaptor made - sounds like something AA should get involved in...

 

[Nitrous SSC]

V8BoatBuilder: So your gona go the same route StadX2 did?

 

[V8BoatBuilder]

V8BoatBuilder: So your gona go the same route StadX2 did?

Possibly. My ideal t-case is the Expedition's 4406. If that fails, it will be the V6 explorer's 4405, just like stadX2.

I'm wondering how close the output shaft of the BW4406 are to it's cousins the BW1345 and BW1356. Both of those cases had fixed yokes for output shafts. Wouldn't it be a kicker if they would swap???

I really don't want to lose the AWD.

 

[tmsoko]

Cannot swap. That was my first thought. The 4406 case is more ovid, whereas the earlier cases are more stretched circle/ellipse. The case halves will not work together. Even if the shafts would interchange, you would need a special cover plate to go where the slip yoke housing was.

 

[Fusion213]

You should see if they make a SYE for the 4406.

 

[V8BoatBuilder]

V8BoatBuilder. What year GEM are you going to use? I wasn't sure if the PATS system was part of the GEM (therefore being a bad addition to a '97) and also how the GEM differed between the vacuum controled front axles (after 1996, I think). So if it matters, we'd need a GEM from a 1997 Control Trac and only a 1997 Control Trac. Or am I giving too much credit to the GEM?

My 1997 doesn't have PATS, and the 1997 Control Tracs didn't have a vacuum disconnect axle either. I'm discounting the 95-96 GEMS since they had the vacuum disconnect control, and the 98s had slightly different wiring from what I hear. I'm shooting for a 97 GEM, since I think its the only one that will work properly for me. It should work with your 96 as well.

I think PATS is in the EEC, not the GEM.

As mentioned in the other thread, I'm going to a junkyard tomorrow to start collecting wiring harness, modules, relays, and possibly a GEM. I'm also hunting parts for an ETAC swap. We'll see what I can dig up, but the yard does have about 10 2nd gen explorers. I'm in no hurry.

 

[tmsoko]

PATS is interconnected between the PATS module, the EEC, and the key/sensor. Not connected to GEM.

 

[V8BoatBuilder]

Todd: How close was the F150 rear driveshaft u-joint to the gas tank? Is this something we could clear with a BFH? Or are our tanks plastic?

Found this on your photo site... http://groups.msn.com/MarlaTodd/ranger.msnw?action=ShowPhoto&PhotoID=102

 

[section525]

It should work with your 96 as well.

That's what I was getting at... since I have a '99 front axle and a 1996 PATS, ECU, etc. I'm think 1997 is the only year I can use as well.

 

[V8BoatBuilder]

That's what I was getting at... since I have a '99 front axle and a 1996 PATS, ECU, etc. I'm think 1997 is the only year I can use as well.

Your 96 has PATS?

 

[section525]

GEM, it says.

 

[V8BoatBuilder]

GEM, it says.

Gotcha

The front axles were all the same starting in 97, and the 96 AWD v8 had a later style axle. The 95-96s control trac v6s are the weirdos.

 

[V8BoatBuilder]

Ok.... news from the junkyard.

I was able to collect almost everything I need for the 4x4 swap electronics, including the t-case harness, TOD relay, shift relay, and dash bezel with switch. My dash bezel/switch was from a 96, so it says "2wd, 4auto, 4low" on the plate, but should work fine. There were some 97s there, but they were either V8s, 2wd, and the one 4x4 had both its GEM and bezel already removed. :fire:

I also took a look at the stock expedition driveshaft. I wish I broght my camera to show you guys, but here's the scoop.

It's a front slip yoke style attachment to the t-case, followed by a double cardan u-joint dealio. The u-joints measure 4.25" in diameter at their widest, so we need roughly 2.25" between the gas tank and the C/L of the t-case output shaft for it to work. The expy rear d-shaft is very close in length to the explorer shaft as well.

More to follow... But I think my hunt is now directed for the following parts:
1) 1997 4x4 Explorer GEM
2) 1997-1998 BW4406 T-case from an Expedition or Navigator, with TOD clutch
3) 1997+ Expedition/Navigator rear driveshaft.

This might be it!! The 4406 is a lot smaller than the NP208 or BW1356, and based on Todd's fitting and using the stock front driveshaft, i'm excited.

 

[section525]

Updaate!