Manual transfer case swap

[1991 Blue danger ranger]

I’m looking to tcase swap my 1991 manual 4.0, with the electric shift 4x4 (manual hubs thank god). My electric shift really hated the cold snaps this winter, and as a result of using it my 4hi no longer works, and my 4lo has become 4hi. Honestly, I don’t really want to diag as I still can use my 4x4, and I already was wanting to put in a manual one. My question is though, how do I rewire for a manual tcase, and furthermore, is it possible for me to just take the linkage off of an already manual tcase and throw it In mine, or do I actually need to get a manual transfer case along with the rest of the business. Thanks in advance!

 

[franklin2]

No wiring involved. The manual transfer case had a switch to turn on a 4x4 light, but your truck is not wired for this so you have no place to hook this up. No need for it really though.

You cannot convert a electric shift transfer case to manual by using a manual shifter. You need the whole manual case and manual shifter. My electric shift transmission adapter did have the hole for the manual shifter, I just had to clean all the dirt out of the hole. I am assuming they continued this theme on up through and yours will have the threaded hole also.

When you are done you will have a bunch of wires at the transfer case that you will not need. Just tie them up out of the way.

 

[gw33gp]

I don't remember where, but I recall reading about someone that was trying to figure out a way to manually shift an electric shift transfer case from inside the cab with some type of cable system. I don't remember if they were successful.

The 02 and 03 non-manual shift transfer case adaptors do not have the holes for the manual shift linkage. The 02 and 03 manual shift t-case adaptors are very difficult to find. It would be best to stick with the earlier manual transfer case and adaptor.

 

[fastpakr]

I don't remember where, but I recall reading about someone that was trying to figure out a way to manually shift an electric shift transfer case from inside the cab with some type of cable system. I don't remember if they were successful.

There have been a few attempts. The Shiftster was marketed for that purpose but went away a while ago.

 

[Uncle Gump]

Behemoth makes one... pretty spendy though.

Borg Warner Electric to Manual Shift Conversion Kit

Electric Motors Love to Fail: It’s frustrating and expensive to have your electric motor fail on your Borg Warner transfer case when you really need 4WD. Get rid of that faulty electric shift motor and bolt on our cable shift conversion kit to get full manual control of your Borg Warner...

www.behemothdrivetrain.com

 

[fastpakr]

Behemoth makes one... pretty spendy though.

Borg Warner Electric to Manual Shift Conversion Kit

Electric Motors Love to Fail: It’s frustrating and expensive to have your electric motor fail on your Borg Warner transfer case when you really need 4WD. Get rid of that faulty electric shift motor and bolt on our cable shift conversion kit to get full manual control of your Borg Warner...

www.behemothdrivetrain.com

Nifty! I hadn't seen that before. Thanks for sharing!

 

[Uncle Gump]

Nifty! I hadn't seen that before. Thanks for sharing!

Just hold onto your wallet!!!

 

[fastpakr]

Just hold onto your wallet!!!

It's a good thing I'm running a manual case already, or that might go on the shopping list for when my ship comes in.

 

[franklin2]

I converted a electric shift to a somewhat "manual" operation and it worked well enough. I cut the wires to the electric motor and ran the motor wires directly to a switch under the dash. Easy to get lost as to what mode you were in, but it did work.

 

[1991 Blue danger ranger]

No wiring involved. The manual transfer case had a switch to turn on a 4x4 light, but your truck is not wired for this so you have no place to hook this up. No need for it really though.

You cannot convert a electric shift transfer case to manual by using a manual shifter. You need the whole manual case and manual shifter. My electric shift transmission adapter did have the hole for the manual shifter, I just had to clean all the dirt out of the hole. I am assuming they continued this theme on up through and yours will have the threaded hole also.

When you are done you will have a bunch of wires at the transfer case that you will not need. Just tie them up out of the way.

thanks much!glad to hear things are identical aside from holes and the motor of course lol. just to clarify, you're telling me i need a manual tcase *along* with the linkage and the rest of the business, and that i just have to cut the motor wires and plug the indicator plug directly into the one i throw in?

 

[1991 Blue danger ranger]

I don't remember where, but I recall reading about someone that was trying to figure out a way to manually shift an electric shift transfer case from inside the cab with some type of cable system. I don't remember if they were successful.

The 02 and 03 non-manual shift transfer case adaptors do not have the holes for the manual shift linkage. The 02 and 03 manual shift t-case adaptors are very difficult to find. It would be best to stick with the earlier manual transfer case and adaptor.

realized that I'm gonna need a tcase, but oh well lol. just gotta spend a hundred more dollars at the pick n pull, but its not so bad. fortunately just going with the older one (Borg warner 1354) as it was introduced i think a year before my truck was made , and its what i have in there now, so shouldn't struggle at all to find one that's applicable.

 

[franklin2]

thanks much!glad to hear things are identical aside from holes and the motor of course lol. just to clarify, you're telling me i need a manual tcase *along* with the linkage and the rest of the business, and that i just have to cut the motor wires and plug the indicator plug directly into the one i throw in?

The one you throw in will not have any connections, but possibly one and you can't use it. You are going to a manual transfer case. That means no electrical, all manual lever in the floor.

 

[1991 Blue danger ranger]

The one you throw in will not have any connections, but possibly one and you can't use it. You are going to a manual transfer case. That means no electrical, all manual lever in the floor.

Just meant the electrical for the lights on the dash