I have a short lasting opportunity to buy a 96 explorer with the 5.0 and awd transfer case for $500. This wasn't a planned swap but i have access to a great welder and fully equipped shop. I've got a 1999 supercab 4x4 ranger with the gutless 3.0. Every problem seems manageable on a budget except for the transfer case. I won't use the explore's because i know that the awd system is junk for my demanding offroad use. From my research the ranger's bw1354 transfer case can handle the power and I want to use it for simplicity. The advance adapter for the 4R70W is wayyyyyy to pricey if I was to go through with this build. Anyone got any pre-owned ones or better ideas?

 

Reads like a good price on the Explorer V8, yes AWD doesn't have 4low and no direct drive, has 30/70 power split vs 50/50 with 4WD

The BW1354 "may" handle the torque of the STOCK V8 as long as you run 29" tires and 3.73 or 4.10 ratios

You want a BW4406, it will bolt to the Explorer transmission and you can use your current electric shift motor, 4406 uses same electric shift as the 1354
The V8 engine and trans needs to be mounted 1/2" over towards passenger side to get clearance for the wider 4406 transfer case

Not sure on the drive shaft changes needed, but you need to do that either way

 

Vancouver, BC has to have something in the water, where you get all this info is beyond me.
You have to live and breathe Ford Ranger.

 

Just like to read and been a DIY wrencher since I got my first erector set in the 1960's, yes I am OLD too