Driveline Fitment

[Maui-sprint]

As for your second question… angle, location and diameter of Speedo hole

So in the pic where you're holding the tailhousing, the one in your hand is the speedo housing? and the original speed sensor housing is installed? which is which?

 

[Maui-sprint]

The wires are part of the electric shift assembly if yours is equipped w that. It would have been bundled into the motor harness. I snipped the plug to get the housing of

So your manual box came with this wire protruding thru the tailhousing but wasn't used?

 

[1984RESTOMOD]

So in the pic where you're holding the tailhousing, the one in your hand is the speedo housing? and the original speed sensor housing is installed? which is which?

The one on the case is the mechanical variation

So your manual box came with this wire protruding thru the tailhousing but wasn't used?

thats my understanding - info during my research was sparse. Maybe someone on here has more info

 

[1984RESTOMOD]

So your manual box came with this wire protruding thru the tailhousing but wasn't used?

Maybe this

Torque on demand

More info here

Seems to be a lot more info regarding 4406 on the explorer forum so I made a post:

My post on explorer forum

 

[1984RESTOMOD]

Based on this article it seems the TOD electromagnetic clutch is an AWD function activated by push button or switch labeled (4WD AUTO) and can be bypassed by simply shifting the shift fork. It acts similarly to a limited slip diff, transferring power when traction is lost by the front or rear.

 

[Maui-sprint]

The one on the case is the mechanical variation

Got it. So I see the difference now. The speed sensor variation has the hole directly over the output shaft. Whereas the speedo hole is offset from the shaft. Sourcing that tail shaft now becomes my challenge. Still may be cheaper for me since shipping wont be as much as shipping a complete case out here. If anyone has one available Im a buyer!

 

[1984RESTOMOD]

Got it. So I see the difference now. The speed sensor variation has the hole directly over the output shaft. Whereas the speedo hole is offset from the shaft. Sourcing that tail shaft now becomes my challenge. Still may be cheaper for me since shipping wont be as much as shipping a complete case out here. If anyone has one available Im a buyer!

free shipping on this one

 

[1984RESTOMOD]

Rough mock up of 4406 support (2 pieces welded together). Thinking between frame rail and bracket I’ll get thick o rings to go on the bolts and act as bushings. What’s your 2 cents?

 

[franklin2]

Don't bother with the o-rings. If bolt goes through a hole in the frame and the nut is touching the frame, that will be your noise transfer point. Most isolation mounts have the rubber molded completely around the bolt.

Also, if you decide to use the o-rings, make sure you use locking nuts. The o-rings will be squishy and if you tighten it enough to stay tight with a regular bolt and nut, you will ruin the o-rings. If you leave it loose enough, then the bolt and or nut will come loose unless you use a locking nut.

 

[scotts90ranger]

I've put 50k miles on my Explorer with the 4406 with just a drivers side engine mount (passenger side had bolts broken off in block, fixed that issue when I rebuilt the engine) and the transmission mount, I'm not sure I'd want to solid mount just the one side of the transfer case unless you have really solid engine mounts and transmission mount it's going to put stress on something weird...

 

[alwaysFlOoReD]

Your cad looks similar to some transverse front engine mount. Go to a junkyard and see what you can adapt.

 

[1984RESTOMOD]

I've put 50k miles on my Explorer with the 4406 with just a drivers side engine mount (passenger side had bolts broken off in block, fixed that issue when I rebuilt the engine) and the transmission mount, I'm not sure I'd want to solid mount just the one side of the transfer case unless you have really solid engine mounts and transmission mount it's going to put stress on something weird...

It will have some play with the size o-ring I intend to use. Seemed awfully heavy hanging off the all aluminum rear housing of the ZF.

 

[scotts90ranger]

I get ya, they're just danglin back there on an f150, same with the way bigger 4407 on the diesel trucks... If there were a way to break one other than full on abuse I'm pretty sure I would have found it , pretty sure tractor pulls aren't recommended and my explorer has done that 3 times

 

[1984RESTOMOD]

I get ya, they're just danglin back there on an f150, same with the way bigger 4407 on the diesel trucks... If there were a way to break one other than full on abuse I'm pretty sure I would have found it , pretty sure tractor pulls aren't recommended and my explorer has done that 3 times

Can't argue with experience! Thanks for your input

 

[Maui-sprint]

What truck did you source the tranny from? Did the factory setup have a separate mount for the transfer case? Is the original case to that tranny lighter? If answers to the last 2 questions are "no" than I wouldnt sweat it.