I was wondering if anyone had any info or experiences swapping the manual FX4 t-case into either a ranger or explorer that has a electronic t-case. My explorer sport has the same engine as the FX4 I'm assuming the t-case would be the same. And if it is will everything bolt up ok? And does the electric case have anything to do with the auto hubs engaging? Any info would be appreciated.

 

Help?

 

They are both Borg Warner 1354 T/C's, so the physical size is the same. The outputs are probably the same, too. My 2003 13-54 manual has flat flanges front and rear. Your 01 Ex doesn't have auto hubs, they are live all the time, so no problem there.

 

didnt they switch the Tcases in the newer explorers to 4406 or 4404 or something like that.

 

4406 is full size 6-bolt (F150/Expedition etc.)
4404 is Explorer 6-bolt 5.0L AWD

I'm pretty sure that the 4405 is the 5-bolt Control Trac unit used in the V6 4-dr Explorers but I don't know if it was also used in the Explorer Sport. Either way, the 4405 and the 1354's are the same size and the same general layout. As long as the outputs are the same or swappable, he should be in good shape.

If it is the Control Trac, then it is controlled by the GEM, so there might possibly be some wiring that needs to be disconnected.

 

The level II case would probably be best because you wouldn't have to worry about wiring up the switch. You'd just have to find the speed sensor or whatever it takes to get it into 4LO

 

my t-case is a BW 1354 with an electric switch to go from 2wd to 4hi or 4lo. The explorer sport that came with a V8 used the all wheel drive crap. I want to get a manual BW 1354 from a FX4 Level 2 so I can have a little more dependablity when out in the woods. The one now tends to act funny when it gets wet and muddy. That and one day I wanna complete a SAS and I think this one will hold up a little better. I think it should bolt up but I wanted to be sure before I went ahead and bought it. Luckily I am fortunate enough to live by the biggest salvage yard on the east coast so I get everything pretty cheap.

 

The manual and electric 1354 T/C are exactly the same except for the shifting mechanism. The cases are the same casting except they are machined differently to accept either the linkage shifter or the encoder motor. Just check to make sure that you have flat flanges front and rear and the case should be a bolt on.

Here's my 2003 LII manual case and you can see the rough cast boss for the shift motor that isn't used on this model. The other pictures show the rear and front driveshaft attachment methods.

 

they used a BW4404 in the Explorers with the "ControlTrac" 4wd option.....it was the 4wd that shifts into 4hi automatically when the rear tires start to slip......

all other Explorer's had the BW1354 in them from '95+........

 

I believe that the V6's had the 4405 Control Trac as an option. The 4404 was the full time AWD case used only with the 5.0L V8.

 

yea you are correct it was the BW4405 in the V6's.....

 

well im gonna up the salvage yard tomorrow and pick one up. I seen a wrecked FX4 2 up there it appeared to hit a tree. hopefully the case is good. ill keep everyone posted on my progress. thanks for the help.

 

You are looking for a Manual Transmission 2002 FX4 or 2003 FX4 Level II. 2004 and up did not have the manual t-case option.