BW441 AWD case


mrtaco

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Can anyone tell me if a explorer/mountaineer AWD transfer case will bolt to a 03 ranger 4.0 manual 4x4 manual trans?
 


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don4331

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Maybe:

We need more information on the Explorer case - date model (should have 4 numerical number after the 2 alpha characters) engine transmission

Picture are worth thousand words.
 

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Thx for the reply. I was under the impression that there was only one true awd case. The bw 4410 and only one manual trans available in that rear ranger?
 

don4331

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So, if I'm interpreting correctl; you are asking if BW4410 off '03 Explorer with 4.0 SoHC* & 5R55W will fit '03 Ranger with 4.0 & M5OD R-1HD:

Reader's Digest answer: no.

Novel length read:
The Ranger M5OD R-1xx uses a 5 bolt basically round pattern pattern on an extended housing, while the BW4410 uses a 7 bolt trapezoidal pattern bolted right to back of transmission.
There are 5 Ranger manuals in '03: (smart @$$ response below, and there are 6 versions not listed as they weren't available in North America and/or '03)​
2.3 M5OD R-1 2wd​
3.0 M5OD R-1 2wd​
4.0 M5OD R-1HD 2wd​
3.0 M5OD R-1 4wd​
4.0 M5OD R-1HD 4wd​

5R55W's in Rangers use an adapter from the 7 bolt pattern of transmission to the 5 bolt pattern of the BW1354 and extended output shaft.

Replacing the rear housing of the M5OD R-1 with one that would bolt to the BW4410 would be seriously expensive proposition - 3.0 to T-5 bell housing runs $2k and that was simpler casting with small volume production.

*I'm not sure if the 4.6 engine Explorer with 5R55S has same transfer case or not.
 

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Excellent info. Basically I want a 5sp manual 4.0 sohc with a true awd. Looks like I’ll be researching the earlier transfer case found in the earlier 96 to 01 trucks
 

don4331

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The easiest AWD solution for Ranger is:

The Dana 28 found in Aerostar: Bolts up to your transmission, provides AWD = 30/60 split I believe but no low range, wiring will allow it to be more/less locked in a 4 High setting. If you search forum you can find examples of its execution.​

The ultimate solution:

http://www.northwestfab.com/5-bolt-ranger-to-6-bolt-round_c_808.html

Then you can install a np242 transfer case with 2 High-4AWD-4 Lock, Neutral & 4 Lo.
np203 is alternative, but a little heavy for Ranger with 4.0 and I don't think it provide 2 Hi.​
np144 also works, but doesn't provide 4 Lo. And you would need to be creative to get 4 lock - wiring for motor and position indicators.​
New Process transfer cases have an actual differential for AWD, versus a clutch in the Borg Warner transfer cases.​

Some adjustment to driveshafts is also required with any of the New Process transfer cases.
 

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I’ve read about the Dana 28. I font think it’s a full time awd unit and it would probably wear out quickly. What about the 4404?
 

don4331

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BW4404 is more/less older model of the 4410; it uses viscous coupling to add power to split power as required.
I'm not sure how much difference there is between a Dana 28 and BW4404 - it almost looks like BW purchased Dana's transfer case division - but I'm not aware of that history.​

I'd be bigger fan of the 4405 - basically 4404 with 4 hi lock + low range of the 1354 - Explorer shifter was 4-Auto, 4 - Hi and 4 - Lo if I remember correctly (I'd have to look at my niece's to be sure.)

Wouldn't you need an Explorer PCM/GEM to control either 4404 or 4405? And I'm not sure how well they would work with '03 dash/manual.
 

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The 4405 is an electronically controlled auto 4wd. It senses slip between the front and rear driveshafts (speed sensors in the T-case) to know when to active “AWD”.

It should be able to easily be made a stand alone system using the selector switch, gem, torque on demand relay, transfer case, and wiring.

Using all 95-96 parts, it would have 2wd, 4wd high auto, and 4low

Using all 97-01 parts would give you 4wd high auto, 4wd high , and 4wd low.

Using the electronics from an Expedition with the Explorer T-case, you should be able to make a system that gives you 2wd, 4wd auto, 4wd lock, and 4low... I say should because I started researching it and found the systems use the same signals, started collecting parts, but never finished and tested it.
 

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This is a street project. Not interested in a low range. So far I’ve learned that the 4404 awd case has a 31 spline input and I will have to swap my trans output shaft to one off a bronco/f150. I know they both have the round style flange from looking at pics. Does anyone know if all bw flanges are the same?
 

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The 5.0 4404 will have 31 splines input and 6 bolt round flange. 4R70W/M5OD R-2 has 31 spline output/6 bolt round flange.
The M5OD R-2, the one out of Bronco/F-150/T-Bird, is completely different transmission, only bolts to something with SBF pattern - 3.8/4.2/5.0​

All Ranger transmissions have 25 spline outputs and 5 bolt flanges.
I'm not even aware of someone who make a 25 to 31 spud for you.​
 

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I read that all the Mazda m50d r2 s were very similar minus the bolt pattern and output shafts. I did not know one was 5 bolt and the other was 6 bolt thou.
 


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