Wanted Need 03-04 M5R1 Manual trans with manual transfer case

[03Level2]

I have an 03 FX4 Level 2 with a manual trans and manual transfer case. The transfer case adapter is cracked badly and I cannot find a replacement anywhere. Unfortunately this is a part that is specific to the 03-04 FX4 Level 2 with manual transfer case because the adapter has both the bosses to mount the transfer case linkage as well as the OSS sensor mounting hole. Earlier rangers with manual transmissions and manual transfer cases do not have the OSS mount. Only the 01+ 4.0 SOHC required an OSS but unfortunately Ford used a separate adapter for trucks with the electronic shift transfer case that does not include the linkage mounting bosses. I will buy a whole trans or just the adapter. Does anybody have one available?

The trans tag should read: 1L54-MA

 

[pjtoledo]

can you post a pic of the OSS mounting hole?
I'm gathering info for future shenanigans.

 

[gw33gp]

There is supposed to be a way to make a bracket for an electronic shift adaptor to convert it to manual shift adaptor. Look in The Ranger Station tech library under transfer cases and M50DR1-HD Transfer Case Shift Lever Bracket. Not a lot of detail is given but it shows the basics. Looks like a lot of measuring and fabrication but it is an option.

You could get lucky and find one but not likely. I tried to get a remanufactured transmission for the manual shift transfer case. Zumbrota had it listed but did not have it. I asked if they could remanufacture mine and they said no. The shop supervisor said he would not touch one. I don't know why because the transmission is the same as the electronic shift transfer case transmission except for the adaptor.

I ended up getting the regular M50DR1-HD transmission and exchanging the adaptors. It worked fine.

Have you considered welding the crack or is it beyond repair? I have seen some weld repairs that seemed impossible. It just takes finding the right person to weld it.

 

[03Level2]

Thanks gw33gp, that certainly looks doable. Might be my best option. Don't know why I didn't consider this. I am a decent fabricator/welder. I do plan to see if I can get it repaired but I wanted to try and find one first because I didn't want to take it apart then find out it couldn't be repaired and have the truck taking up my lift while I figured out what to do.

 

[North Idaho 5.oh]

Ya dude…. Good luck I mean that

 

[03Level2]

Ya dude…. Good luck I mean that

I am going with the build a bracket option. Picking up an 1L54-HB (electronic shift trxfer case) this afternoon from a local yard. Then I'll see if I can get the old one welded.

 

[North Idaho 5.oh]

I am going with the build a bracket option. Picking up an 1L54-HB (electronic shift trxfer case) this afternoon from a local yard. Then I'll see if I can get the old one welded.

Good idea. Include pics if you don’t mind… I would like to see how you do it….

 

[gw33gp]

I am going with the build a bracket option. Picking up an 1L54-HB (electronic shift trxfer case) this afternoon from a local yard. Then I'll see if I can get the old one welded.

If you do the bracket method, it would be good to keep records of what you do. It would be a good addition to the tech library. The article on it leaves out a lot of details.