2WD 4.0L w/auto trans to 4WD w/5speed and manual transfer case

[DangerRanger351]

Hi,

My name is Aaron and im new to TRS on the forums but have used the tech articles a lot. I am needing help with a project. I have a 1994 Ford Ranger ext cab with currently 4.0L with the A4LD and 2wd. I have gotten a dana 35 front axle with manual locking hubs, m50d-r1 5 speed and a manual transfercase, also have the starter. Sorry not sure which transfercase I will look tonight and update yall on that. I figure I still need to change the steering column out, still need to get the pedals and ECM for the 5 speed, and the flywheel, clutch, and slave cylinder. I am also putting in a explorer 8.8 rearend. Is there anything yall know of that I will end to finish making the swap to 4wd? Also any tips for making the swap easier?

 

[DangerRanger351]

the transfer case is a BW1354 mechanical.

 

[4x4junkie]

I hope you're aware that the D35 axle (it's brackets) will not directly fit your 2WD Ranger due to the frame crossmember being different... If you already have some plans drawn up for the bracket that mounts the passengerside axle beam (or were planning on swapping the crossmember out), then disregard.

Everything else should be mostly a matter of removing the auto-trans stuff and replacing it with your manual stuff (the Explorer 8.8" will need the leaf spring mounts on the axle relocated and shock mounts put on it).

Welcome to TRS

 

[DangerRanger351]

I was not aware of it being different. Thanks for the info. Do you know if it will be easier to swap out the member or make a bracket?

 

[4x4junkie]

Depends on your fabrication skills. A lot of force gets put on that bracket when cornering, braking, etc. so if it's not made sturdy, you'll have problems.

If the engine is out of the truck, it shouldn't be hard to swap the crossmember, though a bit time-consuming.

 

[DangerRanger351]

that's a good point. the engine isn't out. so guess i'll pull the engine and swap out the member. guess it gives me the excuse to go ahead and over haul the engine. Thanks again 4x4junkie for the info I sure would have hated to find that out the hard way.