ok so if i got that tranny and transfer case from a ford 4.2 v6 how are the driveshaft legnths going to be? also if thats a manual t-case your using how would i put that into my truck... cutting and welding mounts?
The front driveshaft from the same 97~03 F150 can be adapted to the 98+ Ranger front diff using a conversion U-joint. Lengthwise, the f150 shaft may be a tight fit but it should be doable. Depending on the tolerances of the Ranger, shortening may or may not be required. Instead of shortening, I moved the engine/trans/t-case back about 3/8" to free up some clearance. The F150 front shaft has a built-in slip yoke so it does not have to be exact.
The stock Ranger rear driveshaft would need to be shortened to accommodate the BW4406 case which is much larger in all dimensions. The 4x4 Ranger slip yoke is built inside the shaft but the 4406 has it in the tailhousing. So, one way to do it is by welding a new fixed yoke on the shortened Ranger shaft and using a compatible slip yoke for the t-case tailhousing.
Here are the 2 shafts - stock F150 4.2 front and modified Ranger rear with a 2006 Expedition slip yoke installed. The 150 slip yoke should work as well. The 03 Supercab rear shaft in the picture is 48" center to center on the u-joints.
The M5ODR2 trans mount should match up to the stock Ranger transmission X-member with little or no modifications. The 4406 hangs off the rear of the M5 with no other support.
The holes in the 4.2L M5 bellhousing are set up for metric bolts so they need to be drilled out just slightly to clear the 7/16 bolts for the 5.0. The good news is that the bolt patern is the same and the engine/trans alignment is indexed on two dowel pins which are the same size on both engines.
The M5ODR2 uses the same slave cylinder as the Ranger's M5ODR1 so the clutch hydraulics are compatible.
Both of the stock 150 4.2 manual shifters and the t-case linkage can be used in the Ranger but tunnel mods are needed and boots would have to be adapted.
Possible problem areas:
The 4406 will be very close to the Ranger's driver side frame rail and the slip yoke close to the fuel tank. Slight adjustments may be necessary. In addition to moving the powertrain 3/8" toward the rear as mentioned above, I also moved it 3/8" toward the passenger side. Others have installed the case without this step. This comes down to a combination of personal preference and how the tolerances stack up.
The above info is from my 2003 Supercab. Due to its large size, it is unlikely that the 4406 can be installed in a late model regular cab Ranger without relocating the fuel tank at the very least. Other mods might also be needed.
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