F150 transfer case option for my RANGER 4BT

newbronco2 · Nov 6, 2011

Ok, I need some help. I need a fullsize transfer case for my ranger, is there anything out there I can use that will work with my electronic shifter. I have already found the 4406 manual, and it is probably going to my best/only option, and the advance adapter kit (on back order till 2/1/12 or latter). I just thought I would post and see if anyone else had any ideas before I commited to the 4406.

Truck 99 Ranger extended cab 4X4
3" body lift.
Engine 4bt cummins turbo/intercooled
Transmission - M5r2 -- 1996 f150
Transfer case --- ???

Thanks Tim

superds · Nov 6, 2011

I think the limiting factor for a full size Tcase is whether it fits between the frame rails. Some of them are just too wide to fit without notching the frame.

Why not go with a manual tcase? An NP208 from a mid 80s f150 or FSB will fit in there.

I have heard all the electric shift BWs use the same shift motor, regardless of whether it's a FS or an RBV tcase so there might be hope for that option. I don't know where I heard it from so I can't confirm it. Hopefully someone else can chime in to confirm that for you.

superds · Nov 6, 2011

Ok, I think I remember now, I put a manual shift 4406 in my 99 explorer v8 using these two threads as a guide:

http://www.explorerforum.com/forums/showthread.php?t=166726

http://www.explorerforum.com/forums/showthread.php?t=248285

I think there where several people in the first thread that were using an electric shift 4406 using the stock Explorer shift motors.

newbronco2 · Nov 6, 2011

The electric t-case in a 1997 - 2003 f150 is just a 4406 with a shift motor? I would perfer to have a electric shifted on really, it will be just one less thing I have to build from the ground up. If that is the case, that will be the way I'll go. I think.

Thanks Tim

superds · Nov 6, 2011

Well, there are two different 4406 cases. One is manual shift with a shift lever on the front side and the other is an electric shift with a shift motor on the rear side (similar to what is in the Ranger). As far as I know, you can't make a manual shift into an electric shift without replacing major components (at which point you're better off just starting with an e shift). So if you want an eshift bw4406 find one from a 97+ F150, Expedition or Navigator. I used car-part.com to locate one at a salvage yard near my sister's house a couple hours away from me. I just had to visit her to pick it up!

newbronco2 · Nov 6, 2011

That is what I thought, I found one 1/2 mile down the road at my local salavge yard with 54,000 miles on it $150.00, Looks like my project is going back in the forward direction again.

Thanks for the help.
Tim

superds · Nov 6, 2011

That price looks pretty good. I bought mine for around $125 but had closer to 100k miles.

Good luck with your build. Are you keeping the IFS front or doing an SAS? You should start a build thread on here, I'm sure a lot of people would enjoy seeing your 4bt progress, there's a lot of interest in that engine.

newbronco2 · Nov 7, 2011

I am keeping the IFS. I have acess to a lift so I am going to pull the cab and do it that way. I will start the a build thread when I get all of my parts here.

Tim

snoranger · Nov 7, 2011

The np203, 205, 208, bw4406 should all fit between the frame rails.

The 13-45 and 13-56 need the frame notched, but will kind of fit.

I'm working on the same swap only in a '95 Explorer (same chassis).

Your going to have to modify the oil pan quite a bit to fit the engine and keep 4wd.

Check out my build thread (see link below), it should help you get started.

What AA kit are you waiting for?

newbronco2 · Nov 7, 2011

The kit to adapt the stock t-case to the m5r2. It is on back order untill 2/1/11.

I've already got a powerstroke starter, a m5r2, 4bt cummins. I still need a PS Vacuum pump from a cummin 6bt. I think my oil pan might work out, I am lucky my ranger does not have the axle disconnect on the right side like the explorer.

I have decided on the 4406 -- not sure, weather electric on manual. Leaning to manual, just trying to source all the parts.

Sorry to here about the altima.

snoranger · Nov 7, 2011

newbronco2 said:
The kit to adapt the stock t-case to the m5r2. It is on back order untill 2/1/11.

I've already got a powerstroke starter, a m5r2, 4bt cummins. I still need a PS Vacuum pump from a cummin 6bt. I think my oil pan might work out, I am lucky my ranger does not have the axle disconnect on the right side like the explorer.

I have decided on the 4406 -- not sure, weather electric on manual. Leaning to manual, just trying to source all the parts.

Sorry to here about the altima.

You dont need a kit, all newer Ford tcases (except the dana20 and maybe some other odd-balls) are the same spline and bolt pattern. 6 bolt round and 31 spline.

I only needed very minor trimming to clear the axle disconnect, its the diff that REALLY gets in the way. A 3" body lift will only get you about 26" (maybe a touch more on the Ranger) from the frame to the hood. You cant mount the engine high enough to clear the diff.

4bt dimensions:

I'm have a 13-56m and a NP205, but I might go with a TOD 4406 and keep my Torque-On-Demand.

Thanks, but F@#K that Altima, It should have been driven off a cliff long ago!! :annoyed:

newbronco2 · Nov 7, 2011

Yeah I agree, about the altima time to get back to work on the explore and run over the altima with it.

You should buy the wife an older audi A4 -- I have one, they are nice, can be bought cheap, 4wd, auto or stick, and best of all I heard that they share the same bolt pattern as a 4bt, and you don't need an adapter plate.....

I thought about doing it for about 10 minutes, before I decided on the ranger, I would hate to take apart a good running audi, and more importantly I would hate to waste a good 4bt on a audi.

Yeah I know I am going to have to chop up the oil pan up. Just hoping it will be pretty straight forward.

Tim

newbronco2 · Nov 7, 2011

For those who have been following this thread, I now have a 4406 electric transfer case. I was not able to get a complete 4406 manual case so here I am. I will keep you guys updated soon when I start putting it all back together.

Thanks Tim.

LearjetMinako · Nov 7, 2011

newbronco2 · Nov 7, 2011

LearjetMinako said:

Easy.....

I haven't started this project just yet, next weekend, I am just getting all of my peices together right now, I am just spending money and ordering parts. No point in pictures just yet.

Next weekend the cab is coming off and I am going to start taking pictures as we go.

Tim

F150 transfer case option for my RANGER 4BT

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