Manual Transfer Case Swap - Page 4 - Ranger-Forums - The Ultimate Ford Ranger Resource


Drivetrain Tech General discussion of drivetrain for the Ford Ranger.

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  #76  
Old 03-22-2010
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any more pics?? Looks like its coming out great
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  #77  
Old 03-22-2010
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Yes moar pics man!
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  #78  
Old 03-22-2010
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Nice! yes more pics please!
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  #79  
Old 03-22-2010
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your making this swap complicated.. just put the ****ing case in, and go, who needs lights? **** wheeling with no lights on at all is the ****. especially in the dark and a case of brew
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  #80  
Old 03-22-2010
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Mike you freakin scored on all that stuff.... That uber rare inspection cover with the rubber on it... Retails for $308.. I just checked at ford looking for that lil rubber bushing on the linkage, which ford doesn't list in their system...

EDIT: Oh and according to his computer, he said there's only 17 covers left in the nation lol

Last edited by TrePaul86; 03-22-2010 at 05:42 PM.
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  #81  
Old 03-22-2010
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Quote:
Originally Posted by ranger_1999 View Post
any more pics?? Looks like its coming out great
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Originally Posted by TrePaul86 View Post
Yes moar pics man!
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Originally Posted by Rangerguy View Post
Nice! yes more pics please!
What are you guys wanting pics of? The underside? Interior? Anything specific?
I'll add my pics I've taken to the Manual T-case group tonight. Maybe they'll help someone out thats not sure how things fit together.

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Originally Posted by ranger View Post
your making this swap complicated.. just put the ****ing case in, and go, who needs lights? **** wheeling with no lights on at all is the ****. especially in the dark and a case of brew
The swap is done if you read or viewed the pictures. I just want the thing to work like factory. It'll probably cost me another $20-30 to get the wiring so it'll just plug in, so why not do it? Why even bother to do anything right? I guess I should of just taken a knife to the interior and a torch and a welder to the bottom side.

What makes Bob's truck so bad *** IMO is he's done all those killer mods and yet that truck could pass for stock minus the blower obviously. There is doing a half *** job, or doing the complete job.
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  #82  
Old 03-22-2010
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Originally Posted by TrePaul86 View Post
Mike you freakin scored on all that stuff.... That uber rare inspection cover with the rubber on it... Retails for $308.. I just checked at ford looking for that lil rubber bushing on the linkage, which ford doesn't list in their system...

EDIT: Oh and according to his computer, he said there's only 17 covers left in the nation lol
LOL I think I scored but considering it sounds like Shane gets his stuff for free it might not of been that great of a deal. Most places I called wanted $300-500 just for the T-case. When that guy said he'd sell me the T-case for $400 and throw in the rest of the parts for free, it didn't take me very long to say DEAL!.

You have a source for a cheaper floor plate don't you? I know Shane always posts about having a buddy at a Ford dealer that gets him things at cost.

I'm going to keep my NIB RCM cover. I told my buddy if we were smart we'd but up all those obsolete lvl 2 parts and make a retirement plan out of them. I know an older guy that had a buddy that use to be head parts guy at the local Ford dealer. His buddy would tell him when the stuff was becoming obsolete and being sold off for cheap. He was smart enough to stock up on all those rare parts. He has 10, 427 sideoiler blocks still in the crates.
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  #83  
Old 03-22-2010
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More pics of how it all.. Interior, linkage... People just like seeing it!
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  #84  
Old 03-22-2010
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Originally Posted by Ranger_Envy View Post
LOL I think I scored but considering it sounds like Shane gets his stuff for free it might not of been that great of a deal. Most places I called wanted $300-500 just for the T-case. When that guy said he'd sell me the T-case for $400 and throw in the rest of the parts for free, it didn't take me very long to say DEAL!.

You have a source for a cheaper floor plate don't you? I know Shane always posts about having a buddy at a Ford dealer that gets him things at cost.

I'm going to keep my NIB RCM cover. I told my buddy if we were smart we'd but up all those obsolete lvl 2 parts and make a retirement plan out of them. I know an older guy that had a buddy that use to be head parts guy at the local Ford dealer. His buddy would tell him when the stuff was becoming obsolete and being sold off for cheap. He was smart enough to stock up on all those rare parts. He has 10, 427 sideoiler blocks still in the crates.
Cheaper parts, not cheap... Shane just gets lucky from time to time and runs into deals... He looks a lot harder than me though and knows exactly what to look for. He has 2 of those inspection covers, as well as like 2 of all the Level 2 components, not including the case. He has about 2-3 cases though. The guy he's talking about is one of our buddy's dad who's the parts manager at our local ford dealership, so he hooks us up... He's really good at digging deep to find part numbers and getting us good deals... Just like the L2 trans shifter ball, it retails for like $109 or something like that and I paid $45 for it through some tracking down.

Think about what you have... I bet you have over $1k in parts from a L2 being as rare as they are, that you paid $400 shipped for... I wish I could find a good donor L2 truck to take the few parts I need for cheap, but unfortunately when those come in, they're nab'd up like hot cakes lol
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  #85  
Old 03-22-2010
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i did everything right, i didnt want the stock boots that everyone has problems with with a body lift
everything else is done right.. i dont need a light to tell me im in 4x4
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  #86  
Old 03-22-2010
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Yeah, I didn't like to spend so much on the whole setup when you add the tail shaft and stuff but I know it could easily be parted out for a large profit.

I assume you're aware of the website Car-Part.com--Used Auto Parts Market. Thats how I found my setup.
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  #87  
Old 03-22-2010
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Here are a few more pics. The truck is on the ground so I don't have a lot of room under there when I'm on the creeper. I'm not going to lift it either! Well at least not right now. That coupled with my old as hell 2 megapixel camera doesn't make for the best of shots.




Here is some of the linkage. Its hard as hell to see the linkage up in there anymore. Thats not a tranny fluid leak, thats just the gasket shellac that oozed out. I'm really tempted to try to clean it up but my luck it'll just spring a leak.




After searching through the pics in the Manual T-case group I see that some guys OSS is at 180 degree angle. As you can see from the pics mine is at a 90 degree angle and thats why I was having trouble getting it to fit. I think I may try to swap it out with the 180 as I don't like the wires being bent like that.





Here are some shots of the shifters. As you can see I have the radio out checking out the 4x4 wiring.


This final one shows the gap between the flooring and the bezel.
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  #88  
Old 03-22-2010
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If I were you, I'd take a grinder under the truck with a sanding disc and lightly notch the webbing on the tailhousing til you get that OSS so it doesn't rub, unless you're fine with it the way it is!

Looks killer man. Love the setup! I'll be checking that site out soon :)
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  #89  
Old 03-22-2010
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Originally Posted by TrePaul86 View Post
If I were you, I'd take a grinder under the truck with a sanding disc and lightly notch the webbing on the tailhousing til you get that OSS so it doesn't rub, unless you're fine with it the way it is!

Looks killer man. Love the setup! I'll be checking that site out soon :)
Thanks man. I've definitely got to do something about the OSS so it's now on the list of things to do.

If you've never used that site you can't search for little items. So what I did was search for 2002 Rangers with a manual transfer case. Then I called the yard. It took me a long time to find a yard that hadn't gutted the truck of the drivetrain and sent it to the crusher. So many good lvl 2 parts went to their death.

Tre- When I find a silver bezel to replace the one I have I'll message you.
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  #90  
Old 03-23-2010
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Originally Posted by Ranger_Envy View Post


After searching through the pics in the Manual T-case group I see that some guys OSS is at 180 degree angle. As you can see from the pics mine is at a 90 degree angle and thats why I was having trouble getting it to fit.
That is correct. The 02/03 LII manual extension housing used a straight connector compared to the angled version from your 2004. It is possible that your 2004 harness would plug directly to the 03 OSS. The diagrams of the OSS harness connector look absolutely identical in the 2003 and 2004 Wiring Manuals but that is not 100% conclusive. Here's a photo of the original factory extension housing from my 03 manual LII:

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  #91  
Old 03-23-2010
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That is correct. The 02/03 LII manual extension housing used a straight connector compared to the angled version from your 2004. It is possible that your 2004 harness would plug directly to the 03 OSS. The diagrams of the OSS harness connector look absolutely identical in the 2003 and 2004 Wiring Manuals but that is not 100% conclusive. Here's a photo of the original factory extension housing from my 03 manual LII:

Thanks Bob. I didn't know if that OSS was used on all early Rangers or just the LII's now I know. I'm going to have my buddy at Ford order me the pigtail for the Transfer case and I'll get one of those coming too. Now I just need a junk electric shift motor plug and then try to find similar plugs to the ones used on the 4x4 module to build my adapter harness.
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  #92  
Old 03-23-2010
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Thanks Bob. I didn't know if that OSS was used on all early Rangers or just the LII's now I know.
I still don't know if all of the 01~03 manuals used the straight OSS or not. My guess is that the manuals used the same OSS to reduce plant complexity but that's all it is - a guess.
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  #93  
Old 03-23-2010
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it looks good man, yeah "more pics" was how it all looks now, the linkage and what not. It looks great man. You could get an older boot from early rangers. Like the one I have. it'll cover up that hole.
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  #94  
Old 03-23-2010
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it looks good man, yeah "more pics" was how it all looks now, the linkage and what not. It looks great man. You could get an older boot from early rangers. Like the one I have. it'll cover up that hole.
Thanks for the compliments and all the questions you guys answered through out the process.
pics of your setup?
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  #95  
Old 03-23-2010
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Originally Posted by TrePaul86 View Post
Bob, do you happen to know the part number or price on that inspection cover?
The unique 02/03 FX4 floor plate and lower boots for the 2 manual shifters is 2L5Z-7479-AB. Current price for this discontinued part is $308 and there are just a few left at an obsolete Ford parts warehouse. If you want it, get a new one now or scour the junkyards.
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Manual Transfer Case Swap-fx4-lii-manual-floor-plate-2l5z-7479-ab.jpg  

Last edited by V8 Level II; 03-23-2010 at 12:05 PM.
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  #96  
Old 03-23-2010
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Yeah I just checked yesterday on that cover... I think I can get it for around $250... but I've found some of the offest floor plate older expo's have the rubber insulation piece that is the exact pattern as the level 2 offset... I'll get a pic up in my teaser thread today... I'm gonna secure that to the inspection cover

I don't even have $250 into my whole swap yet... Close, but not yet... As of right now, I've got about $235, and after I buy the t-case shifter arm from Shane, I'll be in it about $315.
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  #97  
Old 03-23-2010
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I just picked up my new floor plate from the dealer this morning. Ryan got my original one for his 4x4 conversion. I'm glad I still have all of the other parts.
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  #98  
Old 03-23-2010
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Trevor I posted a link to a salvage yard that has a toasted LII that they list as still having the T-case in it. So maybe the rest of the hard to find parts are still there like the floor plate. I posted a link to it in this thread.
why cant i find a Junkyard? - Ford Ranger Forum
The net is working to slow here so I can't get the thread open to post the link.


why cant i find a Junkyard? - Ford Ranger Forum

Bob why are you collecting all the old LII parts? Just in case? or going to go back to stock someday?
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  #99  
Old 03-23-2010
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Originally Posted by Ranger_Envy View Post
Bob why are you collecting all the old LII parts? Just in case? or going to go back to stock someday?
I am converting my truck back to a manual transmission and want to adapt the stock LII shifters, boots, floor plate, etc. I thought I could convince myself to be content with the Explorer automatic but I prefer a manual.
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  #100  
Old 03-27-2010
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Well the truck is more or less done. I went to the salvage yard today and got the plug for the T-case, and a LII style (2wd with fog lights) carbon fiber bezel out of a Mazda. I had a spare 5.0 wiring harness out of a Cougar and the O2 plug was exactly the same as the shift motor plug. So I cut the plug off of it and spliced on the T-case plug, now I have a nice harness instead of cutting things up. As for the plugs behind the dash I just installed 2 jumper wires to make the lights on the dash work. I did pick up a set of 4wd module plugs at the salvage yard, so when I get time I'll see if I can find the opposite plug to build the jumper harness out of for that. Unfortunately I don't think the sensor in the T-case works all that great as it lights up when I'm in 4wd but when I put it in 4LO the 4x4 light stays on and the 4LO light will come on if I wiggle the shifter left to right. Then both the 4LO and 4x4 light stay on while in 4LO. Overall I'm pretty happy with it. If I get a chance I might still keep my eye out for a silver radio bezel.

Last edited by Ranger_Envy; 03-27-2010 at 08:12 PM.
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