t case questions,, revised post

[pjtoledo]

apologies for last nights post, it was late and I wasn't thinking properly.

anyway, what I'm doing is putting a 1999 4wd chassis under my 2005 2wd 2.3 manual.
I'm upgrading the front knuckles to '03+ for the 12" rotors, so it's going to be live hubs. that solves the problem of getting the front driveshaft up to speed.

from what I can see, the 1999 t case will be my only concern. if I stay electric and install the 1999 GEM and relays and 4x4 module it will be expecting a signal when the clutch gets the front driveshaft up to speed.
since I don't want to screw with all that wiring,,,,,
I'm going to attempt a manual t case conversion, that way I can leave the 2005 wiring untouched and shift into 4hi any time. since I haven't taken a t-case apart yet, not sure how the front output is locked.
will that be complicated by the t case clutch??
since the front driveshaft is always spinning, will it say screw it and engage?



here's the breakdown of what I'm doing:

2005 2wd body and wiring.
1999 4wd frame, front diff.
2003 front knuckles (upgrades to 12" rotors & live axles).
1999 t-case, manual conversion.
2010 Fusion 2.5 Duratec engine,,,,bad choice, needs some mods to work.
2005 5sp manual tranny, for 2.3 Duratec, tail & main converted to 4wd.
7.5 rear axle with Torsen, 4.10s

the result will be a "2005" Duratec 2.5L 4cyl, manual tranny & t-case reg cab 4x4. something Ford didn't build.

(If I strain my ears I can hear Bobby screaming ECO BOOST )

 

[fastpakr]

How will you shift the electric case manually?

 

[adsm08]

How will you shift the electric case manually?

^That^

 

[pjtoledo]

I'm thinking about that. being a "tinkerer extraordinaire" I look forward to the challenge.


I also have the cable shifter parts from a '89 Taurus SHO laying around someplace. that 5sp transaxle had a 2 cable shifter design. got some 93 SHO atx cables too. maybe I can get some ideas from them.

almost forgot, somewhere deep in the bowels of the garage at about the 27 year ago area is a '78 NP 203 transfer case. still has the shifter, but I think it came out the front. very heavy, wider, bigger splines, and won't fit.(easily)

or just go buy a manual t-case.

 

[fastpakr]

Is a GEM from a 2000+ truck that would have come stock with live hubs an option? That ought to eliminate the issue of any clutch bringing things up to speed I'd think.

 

[pjtoledo]

I have a 2000 with live hubs so I can compare that, provided it's back together at the end of the day,,,it's the wiffies DD.
I really don't want to do any wiring. a manual t-case would be totally invisible to the 2005's wiring making the swap easier.

 

[adsm08]

You are still going to have issues. The PCM needs to communicate for things like trans position, clutch position, etc, to allow the shifts, even with a 5-speed. You computer will need a custom program for that, or it won't have the software to do what it's being asked for.

The electronics involved make this too complicated. I also foresee issues with a cable setup, since there are no hard stops or detents in there to tell you when to stop. The computer knows when to stop the motor.

You should really just find a manual case.

 

[pjtoledo]

slowly giving in to the fact a manual would be better. time to start hitting the yards.

 

[adsm08]

slowly giving in to the fact a manual would be better. time to start hitting the yards.

I'll keep an eye out around here too, not that I have a lot of time to spend at the yard these days.

 

[07nhbpsi]

slowly giving in to the fact a manual would be better. time to start hitting the yards.

Try looking online at inventory at Parts Galore in flat rock........I seem to remember their being a few early 2000s f150s and older rangers pre 2000s’