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Old 08-29-2012
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Need help with transfer case

Yeah, i'm still in AWD and i'd really like to get 4 low and 2wd.

originally i was going to go with the bw4406 manual case but i've been thinking about it more.

how much work would the electric shift to mate with the expo system.

i can find them a lot easier and cheaper around me. and if i didn't have to cut into the truck more that would be great.

hopefully bob can get a word in this thread.
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Old 08-29-2012
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Bob shifted his entire powertrain over to clear the frame rail.

Its a tight fit to say the least.


Many expo owners swap this in, so electrically it cant be that difficult.
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Old 08-29-2012
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I believe ive looked into it and theres some threads over on explorerforum about this.
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Old 08-29-2012
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yeah i was reading about the electric shift with the a4wd thing and control lock or something like that, where they swapped the gem too.

but from what i was reading it should all just hook right up and work if i get the correct tcase.

really would like more input on it though.
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Old 08-30-2012
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Your truck already has gem capable of running a shift motor, is just a matter of getting the right motor and having wired correctly.

Meaning you will need the EVTM for expo and ranger to verify.


Ford is kinda lazy in the tcase department, they may use the same wiring and connectors across the lines.
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Old 08-30-2012
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Why do you need to cut up the Truck when installing a manual T-Case ?

IF you can find it, the floor pan for an FX4 LvL II is cut out for the shifter and unless something changed the frame should be wide enough.

What are you cutting and is there something different on the Expo T/C ?
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Old 08-30-2012
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Quote:
Originally Posted by Vonhanson View Post
how much work would the electric shift to mate with the expo system.

i can find them a lot easier and cheaper around me. and if i didn't have to cut into the truck more that would be great.

hopefully bob can get a word in this thread.
My guess is that the basic electric 4406 from certain F-series and Explorers could be adapted to use the Ranger t-case controls.

There is also another 4406 variant called "Torque on Demand" - a system that can shift in and out of 4WD automatically based on tire slippage. To work as Ford intended, I believe that it would need the donor GEM and wiring methods. Could be a lot more work and potential complications. Definitely need the donor and donee Wiring Diagrams manuals as mentioned above. I don't know which models had the 4406 TOD system. Expeditions, I think, probably others.




Quote:
Originally Posted by Scrambler82 View Post
Why do you need to cut up the Truck when installing a manual T-Case ?

IF you can find it, the floor pan for an FX4 LvL II is cut out for the shifter and unless something changed the frame should be wide enough.

What are you cutting and is there something different on the Expo T/C ?
Compared to the 1350/1354, the linkage and lower shift lever of the manual 4406 is over more to the left and forward. So the factory 4406 shifter setup needs a bezel/boot on the side of the Ranger tunnel to accommodate it. As designed, it won't fit through the FX4 bezel or the factory tunnel cover plate, not even close.

~~~~~~~~~~~~~~~~~

Side comment: maybe it's just me but I would (and have) put the effort into mods for a manual case before I'd opt to install any Ford transfer case shift motor in my truck. In my experience, Ford shift motor/encoder failure is almost certain to happen eventually - it's more a question of when, not if, and it rarely happens at a convenient time.
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Old 08-30-2012
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Hey bob, i read through a bunch of swap threads on explorerforum and a few guys used the TOD tcase, and swapped over the gem, and i didn't read anything about cutting and splicing wires other than the "brown wire mod"

I'd like to go with the manual case, but i can't find much around my area and don't have the time to cut into the truck to modify the linkage either.
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Old 08-31-2012
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Quote:
Originally Posted by Vonhanson View Post
Hey bob, i read through a bunch of swap threads on explorerforum and a few guys used the TOD tcase, and swapped over the gem, and i didn't read anything about cutting and splicing wires other than the "brown wire mod"
I have a number of Ranger and Explorer EVTM/Wiring Diagram manuals but none that include the TOD system. So I can't tell you exactly what's involved. When you say that there should be no splicing required with the TOD GEM into your Ranger, that implies 'plug-and-play' and I am sure that is not the case.
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Old 08-31-2012
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Thats just the how many pages i read on a few guys swapping 4406 into their explorers.

i don't want the tod system, just the plain jane 4406, which from reading only suggests that it should be a simple thing to operate with my stock gem then. but won't really know until i dig into it.
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Old 08-31-2012
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Quote:
Originally Posted by Vonhanson View Post
i don't want the tod system, just the plain jane 4406, which from reading only suggests that it should be a simple thing to operate with my stock gem then. but won't really know until i dig into it.
This is quite possibly true. I looked briefly at the diagram for an electric (non-TOD) 4406 used in the 2002 F150 and it APPEARED that the only difference was the color codes at the shift motor encoder. You'll need to research it further to be sure.
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Old 09-01-2012
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For TOD look under Expedition or Navigator if you got that.

My truck shop cd does not have f150.
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Old 09-03-2012
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i think ima call to a shop i know and see if they have any cases around i could take look at and what not. sorry i've been out of town but def want to get this thing swapped soon.
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Old 10-21-2012
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on my 95 w/97 expo 5.0, a/t and awd t/case i am swapping in 96 bronco elec t/case. direct fit with my original ranger t/case motor installed
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