99 Swapped 5.0 AWD, Front Lockers/Spool?

[NAagard]

I’m starting the process of a complete powertrain swap from a 2000 Explorer 5.0 AWD into my 99 Ranger 3.0 4X4 with manual locking hubs. I’m not wild about the idea of converting from 4WD to full time AWD. This is a dedicated off-road rig and I really need as much traction as possible. I know others have integrated a BW4406 transfer case to keep 4x4 but I really don’t want to go that route.
My question is: in a Ranger swapped with the Explorer 5.0, 4R70W, and BW4404, would there be any issues installing a locker (lunchbox style) or even a spool in the front differential? Then when not needed I could just turn out the hubs? Wondering if that could help add some traction or if anyone foresees any issues?
Thanks

 

[lil_Blue_Ford]

The hubs are a weak link. I don’t know that they will take much abuse and using a lunchbox locker or spool is going to be abusive.

The bad thing about the AWD t-case is that you essentially have 4x4 high all the time, but it can also slip. No low range to help you crawl obstacles.

I kept the AWD t-case on my swap but I lowered mine for street use. If I’d do one of these as an off-road rig I’d definitely be doing a selectable t-case and I’d be considering integrating a doubler.

 

[JoshT]

Allegedly running the Explorer AWD box without a front driveshaft will cause it to burn up in short order. Having the hubs unlocked is mechanically the same thing as having the front driveshaft removed.

Another issue with having the front driveline disconnected on the AWD box is that you effectively have no park. if you park it on any sort of unlevel surface with the frond hubs disconnected there is a high probability that the truck is going to roll away on you.

The AWD box does not have the strength of a proper 4wd box. If you really need the traction, especially enough to justify a front spool or locker, IMO you're going to need the extrength of the 4wd box.

This is coming from people that have the AWD Explorers that you're getting your drivetrain donor from.

FWIW I'm currently in the same position as lil_Blue_Ford, "lowered" AWD '99 Ranger. I'm probably going back lifted and turning it into an offroad/hunting truck in the next few years. Second part of that build will be a 4406 swap along with a rebuilt transmission (unless the trans happens first). Only reason it's coming in second is that it'll likely need at least a custom length rear driveshaft made after the lift, and I don't want to buy them twice. If not for that I'd probably be doing the swap now to see if I were any happier with the street performance.

Also note that companies did make adapters to run the stock Ranger transfer case behind the 4R70W, and I would assume that they still do. If you aren't going to be building the engine and transmission, it will probably handle a mostly stock Explorer 5.0L fine. Same transfer case was used behind the 4.0 SOHC and it made practically the same power stock for stock.

Even considering all of that, you probably don't want a regular locker or spool in the front differential. That is, unless you only plan to go in a straight line, or hop out and lock/unlock the hubvs at EVERY obstacle. Front lockers are not good for turning. If you really want some sort of locker int he front end you either need something that will slip (not sure that they make a front LS diff for a ranger) or a locker that you can lock/unlock from the driver seat, either an air or electric locker. Lock in the hubs when you get to the trail, engage the 4wd (if you've swapped cases) when you need it, engage the locker when you need even more.

 

[Curious Hound]

You do not want a front locker for ANY street driving. And a spool will destroy the front diff even quicker on pavement. I have a lunchbox locker (Aussie) in my front D35 on my Ranger. I tried driving it on pavement last year with the rear driveshaft removed = front wheel drive only while I had a rear axle problem. I can only describe it as "dangerous and not recommended".