Yet another T-Cases to mount to the V8 Thread

[V8BoatBuilder]

Reading this, I'malittle confused here about 96 97 98 years. I have a 96, so for this to work for me I need what here? 96 explorer or expedition Gem?, 96 expedition transfer case?, rear driveshaft,? sport gas tank. It's all plug and play for 96 explorer too right? or no?

On a 96:
1997-1998 T-case w/speedo hole
driveshafts are the same for all years
1997 Explorer GEM, might not be plug and play. 1996 GEM will not work because it needs a vacuum disco front axle.

 

[Joey P]

Thanks you very much. I hope to do this in the near future but for now, I'll probably stick to what I got.

 

[410Fortune]

Hey Joey, I assume that case is holding up?
I will have another one soon, I will be doing this conversion into my blue truck..

 

[Joey P]

The case is great! I think I need a new front driveshaft though. Vibratons and what not coming from the front and I think it's the driveshaft. Bad cv on the driveshaft or something.

 

[boominXplorer]

I have a 2000 so I need a T-case from a 99-01 expo or f150 since my speedo works through the vss in the 8.8? Also what is the difference between a 1356 manual and a 4406 manual in bolting it in? Is it physically the same size with different yokes so custom front and rear d-shafts would be needed. I saw where you explained the differance to johnstone but basically I want the most easiest and fail proof install which makes me want a manual.

Now I saw where you said a 35'' or larger tire could cause problems in the 4406 so do you have any reccomendations on what I do? I am going to be swapping to a 4'' superlift up front so I think the factory F150 d-shaft will fit perfect.

 

[Kris Guilbeaux]

These write ups are Great. Now I am so trying to plan my 4x4 conversion my 99 mountaineer V-8. But unlike some I wanna install a 13-54 Electric. I do not want or need Control Trac. So not I am at a point were I am not sure what I need to do or not do and if the 99 control trac gem would work on my 13-54 t-case? Would I even need the Torque on demand Relay the way I am going?

Any that can help me with these questions would be a great help..

 

[CougarX]

Ok, I've been considering this swap since seeing this write-up, and I've done some research. I can get my hands on a 2000 F150 4406 pretty cheap and was wondering what the difference would be versus a Expedition transfer case. I know the expedition case has the torque on demand whereas the f150 does not but is there anything else that i would have to consider if i used an f150 case?

As far as I can tell from the wiring diagrams, the only difference in the t-cases is the expedition case has front/rear speed sensors where as the f150 case does not. What are these speed sensors used for? Is it for the ABS system or is it for the TOD system? If it is for the TOD system wouldn't this mean that a f150 case would be an even more simple plug and play since all I would have to change would be the dash switch and the GEM would take care of the rest or does it not work that easy?

 

[bobby walter]

you poor *******s

 

[410Fortune]

Kris,
I believe the wire from your Gem module will just remain empty if you go 1354

You will need the wiring, etc from the electric 1350 or 1354, the rangers and BII's (like mine) have the box under the dash and the wiring is much easier to get out of the truck, compared to a Expo. You will need the Advance Adapter AOD-E to 1350 tailhousing and output shaft. The AOD output shaft is a Ford part and it comes with a collar that goes on it to block an oiling hole the 4r70w has. The entire trans must be taken apart to install the new output shaft (good time for at least a "soft" rebuild, valve body updates and a shift kit). My 97 trans with 53K miles looked great inside and only needed a few new parts, solenoids and what not. The total from my trans guy was like $700 to do the whole swap.

After that the 1354 bolted directly up, it is (as you know) about the same size as the AWD 5.0L case.

My 93 1354 uses the same wiring as the 88 BII with the overhead "touch drive" two button BII console. You can use the Ranger dash switch if you want. The Gem moduel will still get the 4hi and 4 low indicator wires, you will have to tap into the trans wiring to get the N sensor and the 5.0L PCM should have a electric shift wire (have to look into that). These two wires are needed for the 1354 electric computer and motor. these may be two wires already going to your control trac relay, I dunno..

The 1354 Case works well behind the 4r70W.....1st gear LOW is NICE

 

[bobby walter]

keep an eye on this one too guys....we can start putting 4r70w's behind them bad ass 4.0s if the testing goes good....



i read this thread, and was wondering if anyone tried a 228 or 229?


keep an eye on this, or actually i will report the results to you guys.


along with some other stuff.


if the guy that lives by me wants to bolt up the jeep 208 to check full fitment issues in a sla vehicle just let me know, we can arrange for a test fit..



grems madness

 

[V8BoatBuilder]

Theoretically, the stock explorer GEM should control a non-tod case's shift motor. However, you are guaranteed blinking 4x4 lights.

 

[410Fortune]

not if the 4x4 lights are wired to the new shift motor and computer
the Gem module wire will go to the new shift computer if needed.
Otherwise I suspect it will act just like a 2wd explorer, where the pins on the Gem module would just go no where.....I am 80% sure the 2wd and 4wd and AWD trucks all came witht he same Gem, I cannot imagine Ford using three they never have in the past on stuff like this.....as the truck frame/shell/body etc are wired up they dont know if its going to be an XLT, base model, v6 or v8, 2wd, 4x4, etc.....not at that time of the assembly. Or at least thats what I have gathered working on these suckers over the years. IS trucks w/o electric seats still have the main body harness plug in for electric seats, etc.

 

[CougarX]

I thought it had been researched that there were three different GEMs? The V8, the 4wd V6, and the 2wd V6.

I guess it does make sense that the 4wd GEMs would work with the 2wd with just dead ends wires, so maybe there is only one GEM. The V8 would work just like the 2wd since there is in T-Case control.

Are the GEMs the same? Maybe different part numbers on the boxes are for different gear ratios and tire sizes. Now that I think about it the wiring diagrams on the Ford Service CD doesn't mention anything about different GEMs and all seem to be wired the same.

 

[V8BoatBuilder]

I thought it had been researched that there were three different GEMs? The V8, the 4wd V6, and the 2wd V6.

I guess it does make sense that the 4wd GEMs would work with the 2wd with just dead ends wires, so maybe there is only one GEM. The V8 would work just like the 2wd since there is in T-Case control.

Are the GEMs the same? Maybe different part numbers on the boxes are for different gear ratios and tire sizes. Now that I think about it the wiring diagrams on the Ford Service CD doesn't mention anything about different GEMs and all seem to be wired the same.

No, the GEMs are indeed different. That's why keeping to your year is VERY important, and selecting the correct application. Using an incorrect GEM could render everything from power windows to the dome light inoperational, not to mention blinking dash lights. A 4x4 GEM should only be used with an A4WD t-case. Everything else should use a 2wd GEM, and rig something up, or not, in the case of a manual t-case.

 

[V8BoatBuilder]

I thought it had been researched that there were three different GEMs? The V8, the 4wd V6, and the 2wd V6.

Actually only two GEMs per year: A4WD (found only in V6 4x4s) and 2WD, used in everything else. (V8 AWD, V82WD, V62WD)

 

[Kris Guilbeaux]

What about the 2001 Sport trac 4x4 GEM the Sport trac used the No-torque on demand Tranfercase (13-54 electric shift) I have a sport trac Transfercase in my garage when I am ready do do this swap. Any one know the difference in this GEM?

 

[CougarX]

So does a non-TOD case have a clutch in it at all? Its my understanding that the 4406 TOD case with an Explroer GEM locks in 4wd high with the clutch and not the shaft. Does this mean that the 4406 non-TOD would not lock into 4wd with an Explorer GEM, only 4low?

Also, if I did use a A4WD GEM with a non-TOD 4406, would it even engage into 4low or 4high since it wouldn't have any input from the front and rear speed sensors?

Also, since the electronics are relativly similar, would it be possible to use a GEM or transfer case module from a 1st gen explorer with the newer 4406 non-TOD? I realize that there wouldn't be any premade wiring to get, but it seems like it would work otherwise.

 

[CougarX]

What about the 2001 Sport trac 4x4 GEM the Sport trac used the No-torque on demand Tranfercase (13-54 electric shift) I have a sport trac Transfercase in my garage when I am ready do do this swap. Any one know the difference in this GEM?

The sport trac doesn't uaually have all the bells and whistles that a Mountaineer or Explorer does. On top of that, the closest you could get yearwise is within 2 years (1st Trac was 01). I highly doubt the GEMs would be compatible. You may get some function from some things, but not others.The only way to tell would be to get wiring diagrams for both and see what everything is, pin by pin, on the GEMs to compare. Even if everything matched up there still may be some programming difference internally.

 

[V8BoatBuilder]

So does a non-TOD case have a clutch in it at all? Its my understanding that the 4406 TOD case with an Explroer GEM locks in 4wd high with the clutch and not the shaft. Does this mean that the 4406 non-TOD would not lock into 4wd with an Explorer GEM, only 4low?

Also, if I did use a A4WD GEM with a non-TOD 4406, would it even engage into 4low or 4high since it wouldn't have any input from the front and rear speed sensors?

Also, since the electronics are relativly similar, would it be possible to use a GEM or transfer case module from a 1st gen explorer with the newer 4406 non-TOD? I realize that there wouldn't be any premade wiring to get, but it seems like it would work otherwise.

Theoretically (and this is just theory), you can fool the GEM by just leaving the speed sensors dangling, since they require a speed of 0 when shifting.

The A4WD case would shift it from 2hi to 4 low, as it only controlls 2 positions on the shift motor. So that kills your 4hi.

Are the 4x4 electronics from a 1st gen explorer/ranger/BII, seperate? Perhaps they can be used stand-alone with your current, 2wd GEM.

 

[CougarX]

There are no speed sensors to dangle on a non-TOD 4406, there is simply no pin on the wiring harness that would connect to the wiring for the speed sensors. Would this still give it a "zero" signal?

Also, isn't there a neutral tow kit available for explorers that unlocks the 2nd position (between 2hi and 4 low) on a stock explorer? This would be the 4-high position on a 4406.