Transfer case Questions. 2x4 to 4x4. 5.0L - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 02-13-2011
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Transfer case Questions. 2x4 to 4x4. 5.0L

Aight so its that next step time. Got a D44 lined up from a Gwagoneer so the SAS is closing near. Here is the question. AODE on my 5.0L engine is 2wd. Best Ideas to swap to 4x4?? also, i want manual shift 4x4. no electronic shift crap.

options;

Find 4wd explorer transfer case (please help on names, part numbers. sad i know) or just pull whole trans/trasnfer combo. convert to manual link?

AA part and different transfer case?

Also, we will most likely making all new trans crossmemebers and rear cross member for drive shaft angle change. its too close right now as it is.
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Old 02-13-2011
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for strength i'd say just go with the bw 4406, i'm currently looking for one as well because i'm running the explorer awd case for right now( i have manual hubs in the front)

i'm also looking for a d44 from a wagoneer you ahole. haha

to make your aode mate up to the 4406 i'm not really sure, i'd just rather stick with the f150 tcase because your making a little more power than the 4wd case is ment for.
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Old 02-13-2011
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Originally Posted by mlw20lu View Post
Find 4wd explorer transfer case (please help on names, part numbers. sad i know) or just pull whole trans/trasnfer combo. convert to manual link?
.
The Expo 4x4 case is a 1354E, just like the Ranger. Or you get the AWD case from a 5.0 Expo. All 5.0 Expos came AWD, they aren't 4x4.

You have 2 options for manual case:

1354M from a Ranger. You will need the advanced adapter for it and custom linkage. Plus new drive-shafts front and back just like any SAS.

or

4406M from a F150. These thing are BIG. They barely fit in the extended cab Rangers frame, but they will work. I believe they bolt up to the 5.0 Expo tranny straight up but they might need an adapter. Not sure about that one. It will also require custom linkage and new driveshafts.

You can get some more info on the TRS tech library page about 5.0 swaps.

Hopefully Bob will chime in, he is one of the few guys running the 4406.
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Old 02-13-2011
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So are you wanting to swap out that trans? To like a AODE 4wd or a C6? You could leave that Tcase and find a divorced 205.

The AODE, AOD, C6, C4 all in 4wd configs are 32 spline output. So a Maunual 1356, Electric 1356, 4406, 4404, 205, 203, D300, etc could all work depending on which way you go.

I have a manual 1356 you can have if you foot the shipping bill. I also have a 205 if you want one.
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Old 02-14-2011
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hmm. I dont neccesarily want to get another tranny. Id rather convert the 2wd i have. if possible. if not then it is what it is ya know. how heavy is that thing?
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Old 02-14-2011
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Originally Posted by mlw20lu View Post
hmm. I dont neccesarily want to get another tranny. Id rather convert the 2wd i have. if possible. if not then it is what it is ya know. how heavy is that thing?
Yeah you can change the output shaft to a 4x4 one.
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Old 02-15-2011
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zach, how much you think it would be to crate ship it down here? ive used Conway shipping before and there good n cheap. dunno if they are in your area. Dont go out of your way just yet tho. Does the 1356 have the shifter ?
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Old 02-15-2011
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I'm gunna run the 205 and you should too. It's gear driven. No chains. It's known as the bulletproof case. Plus you can twin stick it for free. Only thing is it hangs low, you'll wanna clock it up.
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Old 02-16-2011
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Yea i have heard awesome things about the NP205. What is required to clock it and adapt it to my tranny?
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Old 02-16-2011
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Like zach said, they are all 6 hole pattern t-cases and will bolt up. It takes a 32 (I believe) spline input.

To clock it, you can either buy an adapter or some people, i've heard, have just drilled new holes in there tailhousing, each new hole being a little to the right of the oem hole. Once you clock the case your gunna need to re-work the shifter a little bit.

Also with the 205 there is a "torque plate" that bolts on to the drivers side of the case and then bolts to a bushing that is attached to the frame of the vehicle. It helps stabilize the case when torque is applied.

And don't forget your going to need to get a 4wd tailhousing also. It has the Boss bolt holes in it where you bolt the linkage to.
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Old 02-16-2011
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sweet thanks! got a lot more research ahead of me! plenty of time tho.
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Old 02-16-2011
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The BW4406 bolts directly to the 5.0 Ex AWD 4R70W transmission and the splines match. The 4406 manual shift linkage also bolts right up to the extension housing of the AWD 4R70W without modification.

I believe that converting a 2WD 4R70W trans to the AWD version requires a complete teardown because of the output shaft swap.

For those who prefer not to install a slip yoke style t-case like the 4406, Ford also used the similar-appearing BW4407 in F250-up 4x4's and it has a fixed rear yoke. There are fewer 4407's out there making them harder to find and more expensive than the 4406. I don't know if there are any clearance issues with the 4407.

According to one member who has tried it, the 1345 and 1356 are 1.5" wider and won't fit inside the LH Ranger frame rail like the 4406 does (barely).
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Old 02-16-2011
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Hmmm, good info ther Bob. I need to measure my new 205 against my old 1354 and find out what the difference is so I can see what all I'm gunna have to do to make that beast fit. And Mark, your question about the weight, the 205 is heavy. I could barely put it up on my workbench.

EDIT: Mark, if you decide to go with the 205, you can just learn from my mistakes. lol
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Old 02-16-2011
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Bob, once again thank you. With the complexity of it, I will probably pull an AWD trans from the JY and rebuild it with the 4406. that seems the easist route IMO
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Old 02-16-2011
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Be sure to get a 99~01.
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Old 02-16-2011
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The 205 should fit fine. Id go that route if it was me. It wont ever need fixed again. I dont really care if you get mine or not. Id just go with that one. My 1356 does not have the shifter linkage sorry.
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Old 02-20-2011
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SO i took a spare 2wd AODE i had from the 5.0 swap and tore into it. all i can say is F that. I will def be pulling an AWD or $WD AODE 4r70w for the 4wd swap. breaking this down to change out the output shaft is def bot worth it. plus its waaayyyyy beoynd my expertese should something go wrong. I know my limits lol.

Zach I have heard nothing but great things about the 205. how would i adapt it to the 4r70w? I couldnt find anything on advance adapters, but i could be wrong
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