conversion electric to manual, what's possible, pics

[pjtoledo]

compared a manual 1997 to an electric 1999(?)
the particular electric case I have has all the bosses needed.
except for machining, the case front halves are identical.
the front output shafts are 100% swappable between U joint style and CV flange.
the shift forks and rails are identical
the parts needed are:

shift plate
shift plate spring
shift plate pivot shaft
sensing switch for shift plate,,,senses low range???
detent

the red circle above the "98+" is where the detent goes. red mark at lower left will be the shift plate sensing switch.

electric shifting cam assembly, the end (hidden) goes in that tiny hole in the center.

the range shift fork roller rides in the channel next to the flat spring. the front coupler (plastic) fork rides on top of the cam.

range roller not quite in it's groove. as the cam rotates left or right it raises the front engagement plastic fork.

better pic of forks and the cam.

ditto

where the plate spring goes, there is a hard to see tab that secures the top end of the spring.

97 M case with 99 E front output driven gear and shaft

manual shift cam plate, note range shift fork roller in slot. plate spring goes to left then up across a retaining slot.

shift plate spring, shift plate pivot shaft (with machined groove) at bottom.
this is the manual case, note no hole for the shift cam rod in the boss.
hard to see, lower center the detent is protruding from the boss, there is a small circle where it is locked in.
the gray rectangle covering the detent circle is a shadow.

99 E front shaft in the 97 M case

on left 97 case with 99 CV shaft/flange, note hole for switch that senses plate position

hole for shift pivot shaft is already located, needs finished accurately

front outputs swapped between cases.

the hole for the switch lines up with the detent, drill the switch first then use a long tool to do the detent.

did I mention that I like to tear into stuff to see how it works???

 

[Josh B]

Why not just push the button and step on the gas!?

 

[00t444e]

Why not just push the button and step on the gas!?

There will come a time when you push the button and nothing happens.

 

[pjtoledo]

There will come a time when you push the button and nothing happens.

I'm 70, it's already a lot harder to get results after pushing buttons.

 

[wildbill23c]

Been wondering about an electric to manual transfer case swap in my 99 F250 SD....a little knob on the dash doesn't sound very heavy duty to me...and there are 4WD shift codes stored in the computer...not sure why a person couldn't simply swap the cases.

 

[ericbphoto]

compared a manual 1997 to an electric 1999(?)
the particular electric case I have has all the bosses needed.
except for machining, the case front halves are identical.
the front output shafts are 100% swappable between U joint style and CV flange.
the shift forks and rails are identical
the parts needed are:

shift plate
shift plate spring
shift plate pivot shaft
sensing switch for shift plate,,,senses low range???
detent

the red circle above the "98+" is where the detent goes. red mark at lower left will be the shift plate sensing switch.
View attachment 92917

electric shifting cam assembly, the end (hidden) goes in that tiny hole in the center.
View attachment 92918

the range shift fork roller rides in the channel next to the flat spring. the front coupler (plastic) fork rides on top of the cam.
View attachment 92919

range roller not quite in it's groove. as the cam rotates left or right it raises the front engagement plastic fork.
View attachment 92920

better pic of forks and the cam.
View attachment 92921

ditto
View attachment 92922

where the plate spring goes, there is a hard to see tab that secures the top end of the spring.
View attachment 92923

97 M case with 99 E front output driven gear and shaft
View attachment 92924

manual shift cam plate, note range shift fork roller in slot. plate spring goes to left then up across a retaining slot.
View attachment 92925

shift plate spring, shift plate pivot shaft (with machined groove) at bottom.
this is the manual case, note no hole for the shift cam rod in the boss.
hard to see, lower center the detent is protruding from the boss, there is a small circle where it is locked in.
the gray rectangle covering the detent circle is a shadow.
View attachment 92926

99 E front shaft in the 97 M case
View attachment 92927

on left 97 case with 99 CV shaft/flange, note hole for switch that senses plate position
View attachment 92928

hole for shift pivot shaft is already located, needs finished accurately
View attachment 92929

front outputs swapped between cases.

the hole for the switch lines up with the detent, drill the switch first then use a long tool to do the detent.
View attachment 92930


did I mention that I like to tear into stuff to see how it works???

Awesome set of photos and notes. Thanks, PJ.

 

[RonD]

A Bowden cable is what was used for speedometers for a whole lot of years, lol
It takes a rotational force(from transmission gear) and transfers it inside a fixed sheath, to another location(speedometer in dash) but as a "flexible cable"

Seems to me if you were to find the right size Bowden cable you could make a short one that mounts in the cab with a knob(like shiftster size) and then you could mount/clamp other end to transfer case shift rod

They make Bowden cables as flexible drive shafts for many applications, so can handle the torque to shift a transfer case

 

[ericbphoto]

A Bowden cable is what was used for speedometers for a whole lot of years, lol
It takes a rotational force(from transmission gear) and transfers it inside a fixed sheath, to another location(speedometer in dash) but as a "flexible cable"

Seems to me if you were to find the right size Bowden cable you could make a short one that mounts in the cab with a knob(like shiftster size) and then you could mount/clamp other end to transfer case shift rod

They make Bowden cables as flexible drive shafts for many applications, so can handle the torque to shift a transfer case

I think someone did that a year or two ago.

 

[scotts90ranger]

I've contemplated grinding a notch in the electric shift plastic gear and setting it up for a push/pull cable with detents on the shifter assembly for neutral and 4hi, just take the motor off and make a bushing for the cable to go into, sounds simple enough but I never got to implementing since I've found manual cases for everything so far...

 

[00t444e]

Been wondering about an electric to manual transfer case swap in my 99 F250 SD....a little knob on the dash doesn't sound very heavy duty to me...and there are 4WD shift codes stored in the computer...not sure why a person couldn't simply swap the cases.

You can swap to a manual shift transfer case, very easy to do on those.

 

[Josh B]

Been wondering about an electric to manual transfer case swap in my 99 F250 SD....a little knob on the dash doesn't sound very heavy duty to me...and there are 4WD shift codes stored in the computer...not sure why a person couldn't simply swap the cases.

That little button on the dash powers an electric motor, much like the one that starts your engine.
They swap to manual pretty regular, I think they mostly put a floor shifter in it somehow.
It's hard to really come to grips with it but with that motor and transmission installed the drivers knee is almost right beside the shifter. If the seats and stuff was removed in mine I'd be sitting so far back I'd be near sliding off the back of the transfer case

 

[wildbill23c]

You can swap to a manual shift transfer case, very easy to do on those.

Kind of what I was hoping for. I haven't looked around yet at manual transfer cases, or looked at the truck itself...but was told there's probably an access plate or at least markings where the transfer case lever and boot would go through the floorboard of the truck.

The shift motor is working now, but with the lack of use the truck is going to get, I figured I might swap to manual t-case at some point...might be an interesting learning project too LOL. I'm not even sure at this point what transfer cases are used in these trucks, that's how far I've gotten into the research aspect LOL.

 

[00t444e]

Kind of what I was hoping for. I haven't looked around yet at manual transfer cases, or looked at the truck itself...but was told there's probably an access plate or at least markings where the transfer case lever and boot would go through the floorboard of the truck.

The shift motor is working now, but with the lack of use the truck is going to get, I figured I might swap to manual t-case at some point...might be an interesting learning project too LOL. I'm not even sure at this point what transfer cases are used in these trucks, that's how far I've gotten into the research aspect LOL.

Yes there is an acess plate you remove and the holes for the boot and linkage to bolt up are all there. Well worth the swap to get rid of that electric shift junk.

 

[Eddo Rogue]

I'm 70, it's already a lot harder to get results after pushing buttons.

They have pills for that.

 

[wildbill23c]

Yes there is an acess plate you remove and the holes for the boot and linkage to bolt up are all there. Well worth the swap to get rid of that electric shift junk.

Thanks for the information....I figured there may possibly be a plate or other markings in the area where the T-Case lever and boot would go. Now I gotta figure out what transfer case would be the correct one to get.