Manual Transfer Case Swap
#102
#103
Hey Mike. Your interior looks ALOT like mine did when I was twin sticked!! Vinyl floor with that ugly excess hole! lol. Whorage is below. lol.
Anyway, if you were wanting to cure that little hole issue, I was and still will toss in a replacement u-cut-it vinyl floor whenever I have a fully assembled and fully rebuilt 1354M again. And at the same time, add sound deadener. All stock flooring(carpet OR vinyl) have that same huge hole for the shifter or cupholder in it. Carpet guys can get away with making it clean because the carpet sorta blends over the area where two piece join when you put in a filler piece. See Trevor's pics. LMC truck or a couple other places make thick vinyl flooring that's double the thickness of stock flooring. Combine that with a sound absorabant material, you'll be money! Nice quiet ride. They're not precut which is PERFECT for our applications. Plus, you have the option of rear seat deletes if you wanted. Just don't cut the floor for the jump seats. Anyway...just a suggestion and an idear.
Here's a thread with some info on replacement vinyl flooring. BigJohnson in the thread has since finally installed his vinyl and has his own thread too.
clicky: https://www.ranger-forums.com/f40/vi...company-88614/
And the whorage of our similarities...
Oh....my non-manual tcase tailhousings(01, 02, 06) all have 90* OSS sensors. My 02 manual tcase tailhousing has a straight...
Anyway, if you were wanting to cure that little hole issue, I was and still will toss in a replacement u-cut-it vinyl floor whenever I have a fully assembled and fully rebuilt 1354M again. And at the same time, add sound deadener. All stock flooring(carpet OR vinyl) have that same huge hole for the shifter or cupholder in it. Carpet guys can get away with making it clean because the carpet sorta blends over the area where two piece join when you put in a filler piece. See Trevor's pics. LMC truck or a couple other places make thick vinyl flooring that's double the thickness of stock flooring. Combine that with a sound absorabant material, you'll be money! Nice quiet ride. They're not precut which is PERFECT for our applications. Plus, you have the option of rear seat deletes if you wanted. Just don't cut the floor for the jump seats. Anyway...just a suggestion and an idear.
Here's a thread with some info on replacement vinyl flooring. BigJohnson in the thread has since finally installed his vinyl and has his own thread too.
clicky: https://www.ranger-forums.com/f40/vi...company-88614/
And the whorage of our similarities...
Oh....my non-manual tcase tailhousings(01, 02, 06) all have 90* OSS sensors. My 02 manual tcase tailhousing has a straight...
#106
Hey Mike. Your interior looks ALOT like mine did when I was twin sticked!! Vinyl floor with that ugly excess hole! lol. Whorage is below. lol.
Anyway, if you were wanting to cure that little hole issue, I was and still will toss in a replacement u-cut-it vinyl floor whenever I have a fully assembled and fully rebuilt 1354M again. And at the same time, add sound deadener. All stock flooring(carpet OR vinyl) have that same huge hole for the shifter or cupholder in it. Carpet guys can get away with making it clean because the carpet sorta blends over the area where two piece join when you put in a filler piece. See Trevor's pics. LMC truck or a couple other places make thick vinyl flooring that's double the thickness of stock flooring. Combine that with a sound absorabant material, you'll be money! Nice quiet ride. They're not precut which is PERFECT for our applications. Plus, you have the option of rear seat deletes if you wanted. Just don't cut the floor for the jump seats. Anyway...just a suggestion and an idear.
Here's a thread with some info on replacement vinyl flooring. BigJohnson in the thread has since finally installed his vinyl and has his own thread too.
clicky: https://www.ranger-forums.com/f40/vi...company-88614/
And the whorage of our similarities...
Anyway, if you were wanting to cure that little hole issue, I was and still will toss in a replacement u-cut-it vinyl floor whenever I have a fully assembled and fully rebuilt 1354M again. And at the same time, add sound deadener. All stock flooring(carpet OR vinyl) have that same huge hole for the shifter or cupholder in it. Carpet guys can get away with making it clean because the carpet sorta blends over the area where two piece join when you put in a filler piece. See Trevor's pics. LMC truck or a couple other places make thick vinyl flooring that's double the thickness of stock flooring. Combine that with a sound absorabant material, you'll be money! Nice quiet ride. They're not precut which is PERFECT for our applications. Plus, you have the option of rear seat deletes if you wanted. Just don't cut the floor for the jump seats. Anyway...just a suggestion and an idear.
Here's a thread with some info on replacement vinyl flooring. BigJohnson in the thread has since finally installed his vinyl and has his own thread too.
clicky: https://www.ranger-forums.com/f40/vi...company-88614/
And the whorage of our similarities...
I think I might just leave mine alone now as far as the flooring goes. I was in the garage today working and I found a hunk of the vinyl floor mat I cut out in order to install the LII console a long time ago. I removed the shift bezel and crammed a piece of the left over flooring under the edge of the cut out in the floor and the bezel. Its obviously not a perfect fix but makes the gap very hard to see. So I'm leaning toward just keep her the way she is now as I'm tired of working on the thing for now.
I just spent 3 hours ripping the whole setup back out of the truck. Apparently the gasket shellac I got was no good as it would get hard but once the truck was warm the shellac would get all gooey and start leaking. It was just the lightest oil film but it was enough to bug me. I thought about just smearing some silicone on it, but then said screw it and pulled it all apart again. This time I used some Permatex "The Right Stuff" brand silicone and spent about 30 mins cleaning and prepping the surfaces before I put it all back together. I think this time it'll seal, and I'm starting to get very familar with ripping it apart. I hope I don't have to do it anymore.
#107
That tranny you're talking about, was the donor tranny for my manual swap! so between the two of us, we got a lot of parts off that truck, that are on both of our trucks to this day! haha
I'm also really good at tearing my whole drivetrain apart... It's like second nature to me now... After having done it about 3 times.
I'm also really good at tearing my whole drivetrain apart... It's like second nature to me now... After having done it about 3 times.
#108
And this happened....
And now this is happenin'...
lol.
Oh...I got this goin' on too. Just going to pretty much rebuild and make one good case...
For sealing mine, I used just regular old grey RTV silocone/gasket maker. I did the tailhousing in the truck too so I know what you went through. lol. I just made sure I had two clean surfaces then I smeared on a thin layer with my finger on both pieces. Bolted it up...dealt with the tcase. Then filled the trans up. No leaks no nothin'. Was perfect.
The truck I discovered and enlightened Trevor to, I did steal the tailhousing when I stole the tcase. Dropped it all out together too. Was sorta tricky! lol. It took 3 trucks to get all my parts I needed. lol. I only got the linkage, floor plate, tcase, and tailhousing out of it. Some little things here and there, but that's all i stole for the swap.
This is how I left the truck...
how I found it...
#110
I've been doing some tinkering on the truck and here is how she is today. I grabbed this Carbon Fiber Mazda, Lvl II style bezel from a local yard.
I screwed up because the yard had a truck with an extremely scratched up black Lvl II style bezel but I passed on it because I didn't know what I'd do with it. I've now decided that I'll get some spray paint matched to my silver FX4 bezel and paint a black bezel. (even though I hate painted interior parts.) So I went back to the yard to grab the bezel but the truck had just been sent through the crusher that morning.
Now as I said earlier I wanted to clean up the wiring for the 4x4 light and wanted to make it a complete plug in setup. As I said earlier I used an old O2 harness to plug into the old shift motor wiring harness and run to the T-case. For the wiring in the dash. I took a junk 4x4 control module and gutted it. I soldered two jumper wires into the correct pin locations and bolted it back into the truck. She works perfect and all the lights on the dash work correctly. Here is a pic of the 4x4cm.
I screwed up because the yard had a truck with an extremely scratched up black Lvl II style bezel but I passed on it because I didn't know what I'd do with it. I've now decided that I'll get some spray paint matched to my silver FX4 bezel and paint a black bezel. (even though I hate painted interior parts.) So I went back to the yard to grab the bezel but the truck had just been sent through the crusher that morning.
Now as I said earlier I wanted to clean up the wiring for the 4x4 light and wanted to make it a complete plug in setup. As I said earlier I used an old O2 harness to plug into the old shift motor wiring harness and run to the T-case. For the wiring in the dash. I took a junk 4x4 control module and gutted it. I soldered two jumper wires into the correct pin locations and bolted it back into the truck. She works perfect and all the lights on the dash work correctly. Here is a pic of the 4x4cm.
#111
#112
I wish I could get you a better pic Shane but my Camera is 8 yrs old and is more or less worthless. Plus the module is installed now. :P
That 05 module will work in your 01 as I'm using a gutted 01 module in my 04. This is the way I originally solved my 4x4 light wiring issues. I grabbed an O2 plug off a 5.0 wiring harness as it has the same plug as the original shift motor (I believe it has 8 wires running to it) and choose two wires (in my case it was yellow and orange/white) to splice my T-case plug onto the end of it. A spare shift motor plug would work for this as well.
I then followed those two wires up to the 4x4 CM plugs. I then had two jumper wires from the yellow to the blue/blk wire and from the orange/white to the gray wire slipped into place and electrical taped together. Obviously having two plugs taped together with jumper wires running between them wasn't very clean. So what I did was take the 4x4 CM and cut all the terminals loose on the inside of it. I then found the corresponding terminals and jumpered them together. So the junk 4x4 CM is basically just a set of glorified jumper wires, but it looks factory.
When I get home I can look and see what terminals were jumpered, but it would be different probably as there may be wiring differences year to year, and the wires you choose at the shift motor plug.
That 05 module will work in your 01 as I'm using a gutted 01 module in my 04. This is the way I originally solved my 4x4 light wiring issues. I grabbed an O2 plug off a 5.0 wiring harness as it has the same plug as the original shift motor (I believe it has 8 wires running to it) and choose two wires (in my case it was yellow and orange/white) to splice my T-case plug onto the end of it. A spare shift motor plug would work for this as well.
I then followed those two wires up to the 4x4 CM plugs. I then had two jumper wires from the yellow to the blue/blk wire and from the orange/white to the gray wire slipped into place and electrical taped together. Obviously having two plugs taped together with jumper wires running between them wasn't very clean. So what I did was take the 4x4 CM and cut all the terminals loose on the inside of it. I then found the corresponding terminals and jumpered them together. So the junk 4x4 CM is basically just a set of glorified jumper wires, but it looks factory.
When I get home I can look and see what terminals were jumpered, but it would be different probably as there may be wiring differences year to year, and the wires you choose at the shift motor plug.
#113
#114
This was to get the 4x4 lights on the dash to work like factory. After you convert to a Manual T-case none of your 4x4 lights will work anymore, and or your speedo won't be correct when in low. If you want that stuff to work like factory you'll have to do some wiring. I did it this way as now it looks and works like factory without one wire cut or spliced on the trucks main harness.
#115
First off, thanks for the prompt shipping.
This was to get the 4x4 lights on the dash to work like factory. After you convert to a Manual T-case none of your 4x4 lights will work anymore, and or your speedo won't be correct when in low. If you want that stuff to work like factory you'll have to do some wiring. I did it this way as now it looks and works like factory without one wire cut or spliced on the trucks main harness.
This was to get the 4x4 lights on the dash to work like factory. After you convert to a Manual T-case none of your 4x4 lights will work anymore, and or your speedo won't be correct when in low. If you want that stuff to work like factory you'll have to do some wiring. I did it this way as now it looks and works like factory without one wire cut or spliced on the trucks main harness.
So in my case, since I don't have the 4x4 lights, only my speedo will be incorrect?
#117
I'm not in love with the bezel (I actually hate it), its just something temporary until I find a silver 03 Lvl II bezel. The bezel is almost a blueish carbon fiber. Find me a silver one and we'll trade. If I get this weekend off I'm going to yard hunting again and see if I can find a black Lvl II one I can paint. I'll also grab the matching door inserts out of the Mazda I grabbed the bezel out of, and there is an 04 Lvl II in a yard just a few blocks away from this one.
Last edited by Ranger_Envy; 04-13-2010 at 11:33 AM.
#118
Thanks for the info!! That's a great idea I've never seen used!!! I never got around to wiring it all up to the gauges when I had a manual in there because I honestly didn't care. lol. I know what I'm gonna do when I finsih my tcase rebuild!
Need one? I got a black one available. Shoot me a PM, matty boy. lol.
Need one? I got a black one available. Shoot me a PM, matty boy. lol.
#119
#120
Unfortunately, I never had a mint silver LII bezel. LOL. Plus, the silver one is sold anyway. That was the first '03 LII twinstick bezel i've ever seen in a yard...I HAD to nab it. lol. I'd be all over a trade....Let me talk to my brother. We might have a little trade with one of my 'keeper' black bezels if you're interested. Or.....That one I PM'd you about...I was stupid and there is some rubber flake crap. But you're just gonna paint it anyway right? Maybe that + a little cash or something. I'll talk to Grant and shoot you a PM tonight about it. I know he's been hot for a CF bezel for a while.
#121
Unfortunately, I never had a mint silver LII bezel. LOL. Plus, the silver one is sold anyway. That was the first '03 LII twinstick bezel i've ever seen in a yard...I HAD to nab it. lol. I'd be all over a trade....Let me talk to my brother. We might have a little trade with one of my 'keeper' black bezels if you're interested. Or.....That one I PM'd you about...I was stupid and there is some rubber flake crap. But you're just gonna paint it anyway right? Maybe that + a little cash or something. I'll talk to Grant and shoot you a PM tonight about it. I know he's been hot for a CF bezel for a while.
Ahh, ok. I thought you mentioned in another post that you had special mint condition parts for that "just incase you ever go back to the Lvl II setup."
#122
I do....but....they're black. lol. I never liked those Silver bezels ontop of the dark grey...just looks funky to me. lol. And yes....I have mint floor pieces for when I do go back. The first chrome floor bezel thing I got was effed up from a botched bodylift job that no one used a shift extention on...and the boots are efffffffffffffffffffed. lol. So to put it one way, it was a training bezel on perfecting bodylifts w/ L2 bezels. lol.
#124
It is possible and actually fairly easy. Just run two wires from the t-case switch to the cluster plug. Then make sure that the branch circuit from the 4Low light to the PCM is present in your harness.
#125
It is possible and actually fairly easy. Take a look at post #74 of this thread where I describe how to convert the 2004~2006 electric shift lights to work from the manual shift switch on the T-case. 2001~2003 would follow the same procedure except the 4x4 Module plugs are located behind the passenger kick panel.