Electric Transfer Case to Manual Transfer Case Swap

[kozak]

I have a 93 Explorer with the electric push button 4x4, Borg Warner 1354. I would like to switch over to a manual. I have found a manual transfer case from an 88 Ranger, I believe it would be a Borg Warner 1350. Is there any major differences between the two transfer cases? Another thing I would like to know is, is it a bolt in swap, or would I be modifying drive shafts etc. Is there anything else to the swap, other then bolting it up, and rigging up the shifters in the floor ?

 

[mjonesjr]

The transfer case is bolt in, but you have to find a shifter to work. I think there was like 20 something different shifters for the 1350.

You also have to modify the 1350 front drive shaft by shortening it 1".

 

[kozak]

The person I got the 1350 from has an 88 Ranger as a part truck, so couldnt I just grab the shifters out of it? I have no problem hacking up my Explorers floor wherever the shifters need to go.
Thanks for the help, good to know about the drive shafts, luckily I know some good welders.

 

[Wicked_Sludge]

there arent even close to 20 different chifters. theres like 3. you need one from an M5OD truck (90+ is a safe bet). the shifter out of the 88 wont work, it uses a different transmission (the linkage bolts to the side of the trans.).

you can shorten the front driveline, or you can get one from a d35/1350 equipped truck (the d28 driveline is too long).

the hole is already in your floor. under your carpet there is a bolt-in plate that blocks the shifter holes. you just need to find the appropriate plate for your setup (auto/manual trans). it would probably be easiest to get the linkage, plate, shift boot(s), and boot trim all from the same donor.

it can be a bolt in swap, you just have to find the right parts.

 

[Hahnsb2]

the shifter out of the 88 wont work, it uses a different transmission (the linkage bolts to the side of the trans.).

Yes it will...

 

[surffishin07]

i did this swap on my 94 ranger with a 5spd. i got the case from a 88 ranger with an automatic. the only modification i had to do was swapping the rear output flange from my old case to the new one all that takes is a 30mm socket and some locktite. the shifter from the auto bolted to my 5spd and the drive shaft barely fit just do your measurements first. as for the floor pan i just cut mine with tin shears. good luck its not that hard just check everything first.

 

[kozak]

Okay, well today, I went to the local wrecking yard here. Found a 93 Explorer, same as mine, looked inside, seen the shifter, looked under neath, an behold the 1354 manual transfer case is still there. It looks mint, I am going to grab that tomorrow, as well as the shifter and floor plate. Would I still have to modify drive shafts, would I have to get one shortened, or get the one from the donor explorer ? Does anything need to be wired up ? I really appreciate all the help, thanks to all of you.
I would feel much better and safer with the 93 1354 then having the older rusty 88 1350 under the truck.

 

[mjonesjr]

If you have a Dana 35 front axle, then you wont have to modify the front axle. Just make sure you grab the front drive shaft off the Explorer if you don't already have a 1354 front drive shaft.

 

[kozak]

Yes, the front axle in my explorer is a dana 35, and I got a 1354 electric case, so does that mean the front drive shafts would be the same ?

 

[mjonesjr]

Yup.....

 

[kozak]

Excellent, thank you very much.

 

[kozak]

I got the manual Borg Warner 1354 transfer case, shifter, floor plate, and all necessary bolts today from the wreckers. There was some wiring, and what looked like to be a cable hooked into it, I did not retrieve those as I did not have enough time. I am hoping that my electric transfer case has the same things.
I just have to get fluid and gasket sealant before I do the conversion, I will post pics an results when finished.

 

[mjonesjr]

The wire hooked to the transfer case was for the dash lights. I wouldn't bother with it.

There isn't a cable hooked to the BW1354 manual.

 

[Wicked_Sludge]

what looked like to be a cable hooked into it

breather tube maybe?

you'll want one on there if it was.

 

[kozak]

There were 2-3 colored wires, and something that looked like a bicycle brake cable, running from the transfer case, up through the fire wall, under the dash and behind the dash gauge instrument cluster. When I un hooked the wire and cable like thing from the transfer case, there was a little metal rod type thing that came out, I saved that. Below is a picture of where the wires were hooked into, and the metal rod that was inside.