Manual Transfer Case Swap
#26
My bet is that he mistaken about the bezel being aftermarket. There is no aftermarket bezel available for these trucks. He's probably just never seen one before and assumed it was aftermarket. It wouldn't be the first time I've heard someone call the stock level II bezel an aftermarket part.
I have the rubber floor mats. Thats going to put a damper on my mood.
#27
Well good news! I emailed a picture of the RCM cover to the salvage yard and pics of a stock FX4 level 2 setup to them with a list of parts I need included. The guy there said that after looking at the pics everything in the truck is stock. He said he'd make sure everything was included in the picture. I then asked him what he'd charge to throw in the Fx4 transmission shifter and he said he'd throw it in for free his comment was "it'll just get thrown away so I might as well give it to you." Sweeet! The parts were still all in the truck so they'll be removing them and shipping them my way. Once I have them in my hands I'll post where the yard is at if anyone wants to go pick the bones and get them some tow hooks and other level 2 stuff. So far every other salvage yard i've talked too with FX4 level 2's just yank drivetrains and send the rest to the crusher.
#30
Yep! Its supposed to me a complete set up everything I need to do the swap.
Transfer case
linkage
T-case shifter
tranny shifter
Bezel
RCM cover
Anything else I need to get added?
The thing thats scary is that the stuff has to be removed by some guy at a salvage yard. Lord knows they're not the most gifted when it comes to parts removal. I'm not worried about the T-case and stuff but I hope the bezel gets removed in one piece.
Transfer case
linkage
T-case shifter
tranny shifter
Bezel
RCM cover
Anything else I need to get added?
The thing thats scary is that the stuff has to be removed by some guy at a salvage yard. Lord knows they're not the most gifted when it comes to parts removal. I'm not worried about the T-case and stuff but I hope the bezel gets removed in one piece.
#31
As Ryan said, be sure to get the floor plate as well. The floor plate fits into the large opening in the tunnel under the carpet and adapts for the various transmission and t-case combos and shifter arrangements. There are different plates for auto, manual and manual/manual. You need the special FX4 manual/manual plate because it has a large rubber diaphram that accommodates the two shift levers. Without it, you would have to cut a custom hole for the t-case shifter and make or adapt an inner boot. The FX4 part will bolt directly into your tunnel without modification and keep dust, water and a lot of noise out of the cab.
#32
#33
As Ryan said, be sure to get the floor plate as well. The floor plate fits into the large opening in the tunnel under the carpet and adapts for the various transmission and t-case combos and shifter arrangements. There are different plates for auto, manual and manual/manual. You need the special FX4 manual/manual plate because it has a large rubber diaphram that accommodates the two shift levers. Without it, you would have to cut a custom hole for the t-case shifter and make or adapt an inner boot. The FX4 part will bolt directly into your tunnel without modification and keep dust, water and a lot of noise out of the cab.
Transfer case
linkage
T-case shifter
tranny shifter
Bezel
RCM cover
Floor plate
#35
#36
Thanks RazorsEdge, I'll make sure they toss it in. I slid under my truck the other night and saw that there appears to be a hole in the floor for the T-case shifter already. So the plate just more or less bolts down and holds the rubber boots? I'll make sure they give it to me but wouldn't it probably be the same as earlier Rangers with twin sticks since the body really hasn't changed any?
#37
Thanks RazorsEdge, I'll make sure they toss it in. I slid under my truck the other night and saw that there appears to be a hole in the floor for the T-case shifter already. So the plate just more or less bolts down and holds the rubber boots? I'll make sure they give it to me but wouldn't it probably be the same as earlier Rangers with twin sticks since the body really hasn't changed any?
This plate makes a huge difference in the cab noise, I ran without it for several months and when I was finally able to get my hands on one of these and put it in my truck the cab was much much quieter.
If you decide you don't need it you'd probably be able to sell it for top dollar as well.
#38
#42
#43
Ok well I've been very anxiously awaiting the arrival of the parts to see what I got and what condition it arrived in. Sometimes salvage yard guys are a little rough with stuff. I'm happy to say that the parts are in awesome shape and I believe I got just about everything I need.
You can see in the pics that for some reason they removed that cast steel donut shaped ring off the T-case but included it. What does that thing actually do?
The tailshaft housing and my spare RCM lvl 2 cover are sitting at my buddies dealership and I should have them Saturday. I'm cleaning up all the parts and I'm going to try to get the floor plate and tranny shifter installed by Saturday. That way all I have to do is the tail shaft and T-case swap. Call me crazy but it sure seems like it should go quickly.
One question to the guys with twin sticks. I've read that you can add some wires from the T-case up a plug in the cab and have the lights on the dash work when you put it into 4wd. I don't have any problems adding the wires but I'm wondering do the lvl 2's have a special plug in harness? or is the chassis wiring harness different to accommodate the plug on the manual T-case? I'm wondering if I should call the salvage yard and see if they'll sell me the harness. I'd love to have the complete factory setup.
You can see in the pics that for some reason they removed that cast steel donut shaped ring off the T-case but included it. What does that thing actually do?
The tailshaft housing and my spare RCM lvl 2 cover are sitting at my buddies dealership and I should have them Saturday. I'm cleaning up all the parts and I'm going to try to get the floor plate and tranny shifter installed by Saturday. That way all I have to do is the tail shaft and T-case swap. Call me crazy but it sure seems like it should go quickly.
One question to the guys with twin sticks. I've read that you can add some wires from the T-case up a plug in the cab and have the lights on the dash work when you put it into 4wd. I don't have any problems adding the wires but I'm wondering do the lvl 2's have a special plug in harness? or is the chassis wiring harness different to accommodate the plug on the manual T-case? I'm wondering if I should call the salvage yard and see if they'll sell me the harness. I'd love to have the complete factory setup.
#44
Ok well I've been very anxiously awaiting the arrival of the parts to see what I got and what condition it arrived in. Sometimes salvage yard guys are a little rough with stuff. I'm happy to say that the parts are in awesome shape and I believe I got just about everything I need.
You can see in the pics that for some reason they removed that cast steel donut shaped ring off the T-case but included it. What does that thing actually do?
The tailshaft housing and my spare RCM lvl 2 cover are sitting at my buddies dealership and I should have them Saturday. I'm cleaning up all the parts and I'm going to try to get the floor plate and tranny shifter installed by Saturday. That way all I have to do is the tail shaft and T-case swap. Call me crazy but it sure seems like it should go quickly.
One question to the guys with twin sticks. I've read that you can add some wires from the T-case up a plug in the cab and have the lights on the dash work when you put it into 4wd. I don't have any problems adding the wires but I'm wondering do the lvl 2's have a special plug in harness? or is the chassis wiring harness different to accommodate the plug on the manual T-case? I'm wondering if I should call the salvage yard and see if they'll sell me the harness. I'd love to have the complete factory setup.
You can see in the pics that for some reason they removed that cast steel donut shaped ring off the T-case but included it. What does that thing actually do?
The tailshaft housing and my spare RCM lvl 2 cover are sitting at my buddies dealership and I should have them Saturday. I'm cleaning up all the parts and I'm going to try to get the floor plate and tranny shifter installed by Saturday. That way all I have to do is the tail shaft and T-case swap. Call me crazy but it sure seems like it should go quickly.
One question to the guys with twin sticks. I've read that you can add some wires from the T-case up a plug in the cab and have the lights on the dash work when you put it into 4wd. I don't have any problems adding the wires but I'm wondering do the lvl 2's have a special plug in harness? or is the chassis wiring harness different to accommodate the plug on the manual T-case? I'm wondering if I should call the salvage yard and see if they'll sell me the harness. I'd love to have the complete factory setup.
The round doodad thing they removed is some sort of balancer and the t-case drain plug is behind it which is probably why they removed it. As for the 4x4 light wires I doubt your truck is prewired for the manual case setup. It would be super easy to run the two wires if it comes down to it though.
Ever figure anything out about the carpet? Or rubber floor or whatever.
#45
Nice!
The round doodad thing they removed is some sort of balancer and the t-case drain plug is behind it which is probably why they removed it. As for the 4x4 light wires I doubt your truck is prewired for the manual case setup. It would be super easy to run the two wires if it comes down to it though.
Ever figure anything out about the carpet? Or rubber floor or whatever.
The round doodad thing they removed is some sort of balancer and the t-case drain plug is behind it which is probably why they removed it. As for the 4x4 light wires I doubt your truck is prewired for the manual case setup. It would be super easy to run the two wires if it comes down to it though.
Ever figure anything out about the carpet? Or rubber floor or whatever.
As for the carpet/flooring I'm some what undecided. I really want to do it right but to do so I'd have to find some nice rubber flooring out of an auto, 2 door extended cab, and that might be tough. At this point I might consider doing it though but I'm going back with rubber flooring. We own a concrete company and I swear that sand gets worked into carpet and you can never get it out. What did you end up doing for the flooring?
I'm hoping we have terrible weather this weekend like they forecasted so I can hit up the salvage yards on saturday. Also it'll give me a chance to test out the twin sticks if I get them installed.
I've gotten the old floor plate out so far and I've found out that the top of my shifter is covered in a flim of oil. Apparently it needs a new seal/gasket. I guess I need to find out whats involved in fixing that before I button it all up.
#46
It is simple to add a pair for the lights. Hopefully, the guys who sent the t-case also included the pigtail for the switch. If not, you can order a repair pigtail from Motorcraft for way more than it's worth.
Possible solution: There are aftermarket companies that sell preformed, OEM style carpets or rubber floors and the final trimming is left to the customer. As far as I can tell, those are supplied with no shifter cutout at all. I don't know how those compare to the factory carpet in terms of fit or quality.
Auto Carpet for Car, Truck, Van - Automotive Replacement Carpets
While it's apart, take a quick look at the 3 rubber plugs that close the shift rail holes on the back of the top cover. They sometimes leak and later fall out and then drop enough oil to burn up the transmission. Not cool.
Last edited by V8 Level II; 03-19-2010 at 05:56 AM.
#48
Nope.
It is simple to add a pair for the lights. Hopefully, the guys who sent the t-case also included the pigtail for the switch. If not, you can order a repair pigtail from Motorcraft for way more than it's worth.
The auto floor also has a large hole that is covered by the cupholder/consolette. At least every one I've seen does. Only the 02 FX4 and 03 LII manuals have the carpet with the small double shfter cutout and there is no rubber floor for that year or any other year that will match.
Possible solution: There are aftermarket companies that sell preformed, OEM style carpets or rubber floors and the final trimming is left to the customer. As far as I can tell, those are supplied with no shifter cutout at all. I don't know how those compare to the factory carpet in terms of fit or quality.
Auto Carpet for Car, Truck, Van - Automotive Replacement Carpets
Could be a real leak. If the truck has been used a lot off road, it may only be slosh - the transmission breather is built into the shifter tower and can lose a SMALL amount of oil under the right conditions.
While it's apart, take a quick look at the 3 rubber plugs that close the shift rail holes on the back of the top cover. They sometimes leak and later fall out and then drop enough oil to burn up the transmission. Not cool.
It is simple to add a pair for the lights. Hopefully, the guys who sent the t-case also included the pigtail for the switch. If not, you can order a repair pigtail from Motorcraft for way more than it's worth.
The auto floor also has a large hole that is covered by the cupholder/consolette. At least every one I've seen does. Only the 02 FX4 and 03 LII manuals have the carpet with the small double shfter cutout and there is no rubber floor for that year or any other year that will match.
Possible solution: There are aftermarket companies that sell preformed, OEM style carpets or rubber floors and the final trimming is left to the customer. As far as I can tell, those are supplied with no shifter cutout at all. I don't know how those compare to the factory carpet in terms of fit or quality.
Auto Carpet for Car, Truck, Van - Automotive Replacement Carpets
Could be a real leak. If the truck has been used a lot off road, it may only be slosh - the transmission breather is built into the shifter tower and can lose a SMALL amount of oil under the right conditions.
While it's apart, take a quick look at the 3 rubber plugs that close the shift rail holes on the back of the top cover. They sometimes leak and later fall out and then drop enough oil to burn up the transmission. Not cool.
I might of lucked out then and the leak from the shifter is one just from sloshing. The tranny isnt even wet at all its just the stop of the shifter base and the bottom of the old floor plate foam was just a little damp. I'll double check those rubber plugs though. My cousin lost his tranny in his explorer that same way so I know what it can do.
I'll just run wires for the transfer case then if there is no special harness. Apparently this was one of those good salvage yards that actually unplugs stuff rather than cutting every electrical connection. So finding the plug will suck. I hope my buddy at the dealership can get it for me at a decent price.