5.0 Transfer Case Troubles

[glamisbound01]

I have a short lasting opportunity to buy a 96 explorer with the 5.0 and awd transfer case for $500. This wasn't a planned swap but i have access to a great welder and fully equipped shop. I've got a 1999 supercab 4x4 ranger with the gutless 3.0. Every problem seems manageable on a budget except for the transfer case. I won't use the explore's because i know that the awd system is junk for my demanding offroad use. From my research the ranger's bw1354 transfer case can handle the power and I want to use it for simplicity. The advance adapter for the 4R70W is wayyyyyy to pricey if I was to go through with this build. Anyone got any pre-owned ones or better ideas?

 

[Snoranger]

Use a BW4406 from an F-150.

 

[glamisbound01]

It's an option. I just don't know if I could afford a seperate transfer case and two custom driveshafts.

 

[fastpakr]

Transfer case from an F150 won't be expensive if you search a bit. Driveshafts aren't bad if you scavenge and have them cut to fit.

 

[Snoranger]

It's an option. I just don't know if I could afford a seperate transfer case and two custom driveshafts.

A 4.6L F-150/expedition front driveshaft with a 1-0134 ujoint at the front should work. That’s what the Explorer guys use when they swap to the 4406.
I’m sure there’s a stock solution for the rear driveshaft. It’s going to take you some research.

 

[glamisbound01]

Is there any fitment issues with the 4406 besides the driveshafts? I've seen that some guys had to shift the whole engine and transmission over a couple inches.

 

[fastpakr]

I ground down some of the tabs on the case a bit and removed the rubber damper around the shaft by the fuel tank.

 

[glamisbound01]

Ok. If that is all I have to do it's no big deal. What exactly was your configuration?

 

[fastpakr]

I put a manual shift 4406 in my 99.

 

[glamisbound01]

Yeah see I'm wondering if the 4406e is different in size to your 4406m

 

[Snoranger]

The housing will be the same size. My only concern would be the shift motor location in relation to the gas tank.

 

[don4331]

4406e is the simple solution: It will install on an SuperCab without hitting anything, and will connect right up to Ranger wires to look very factory. Shifts like it is factory too.

My solution was a NP242, but I did pay a couple hundred bucks* for the correct input adapter. Front driveshaft is out of the Explorer. Rear driveshaft is from a long bed Ranger I believe - the NP 242 having the slip yoke like the 4x2 Ranger; and long box Ranger being the correct length.

*OK, I spent about $300, but I put in new chain and while I was in, found the filter on the oil pump was damaged, so fixed that while I was there anyways. NP242 gives me 2H, 4FT, 4Lock, N & 4 Lo. I was stucker for the 4 full time - I hadn't found out how easily the 4406e went in when I did mine...