Transfer case options

[steven]

Working on gathering parts for 5.0 swap in my 91 STX, motor is 91 mustang with AOD. Needing input or ideas on transfer case options. I have the good 2wd AOD and can purchase adapter from advanced adapters, or possibly put a 4wd output shaft in the 2wd trans and use a full size tcase, just not sure how they fit between frame rails. Trying to not break the bank, already spent more than I wanted.

 

[don4331]

Divorced transfer cases are rare beasts.

To change Ford Automatic from 2wd to 4WD, you pull all the guts out of the transmission from the front, replace the output shaft, then reinstall it all.

Once you have converted to 4WD transmission, manual shift 4406 would top my list.

 

[rubydist]

In case that was not clear enough, the first part that goes in the back case is the output shaft, so you literally have to take everything out of the trans to change that shaft. As long as you are doing all that, you had just as well rebuild it.

 

[steven]

Is there any issues as far a physically fitting the 4406 in between the frame rails?

 

[don4331]

BW4406 would be the one "v-8" case that fits between frame rails.

Others like BW1356 need "light" adjustments to fit.

 

[steven]

I assume with the 4wd output shaft and the correct adapter housing it will bolt to the back of the AOD. What output spline count is the 4WD shaft?

 

[Shran]

BW4406 would be the one "v-8" case that fits between frame rails.

Others like BW1356 need "light" adjustments to fit.

NP205 will fit pretty easily, provided a transmission with the old "full size bolt pattern" output housing is used.

Another option is a Bronco Dana 20, you can get an AOD to D20 adapter from Advance Adapters. Those t-cases are tiny and light and you can do a 3.15:1 low range conversion on them and twin stick but that would be expensive and a D20 is probably somewhat hard to find.

Atlas is of course an option but even more spendy!

I would avoid the divorced t-case route, that seems to be the one everyone talks about but nobody ever does it because of all the negatives that come along with that style of setup.

 

[don4331]

I consider NP203 & 205 too heavy - don't they weigh over 150 lbs for something as light as a Ranger.

And Bronco Dana 20s are rare as hen's teeth locally - even Jeep Dana 20s aren't common.

While I can find manual 4406 on at least semi regular basis at local wrecker.

 

[Shran]

203 is a huge heavy pig, for sure! 205's are pretty heavy too, supposedly about 140lbs? I was going to guess about a hundred but Google corrected me. I've got a NP435 and 205 in my Ranger... that combo is probably at least 100lbs heavier than the FM145 and 1350 I took out.

 

[steven]

Anyone know a good source for output shaft and also adapter housing? Is that a wrecking yard thing?

 

[Shran]

I'm sure you could find one there... but the trick is finding a place that will sell you just those parts, and most won't, you'll have to buy the whole trans. And usually they assume it's "good"... the junkyard I usually go to has no idea if a part is good or not. So use your judgement there. Another source is a transmission rebuilder shop, they all keep cores and stocks of parts on hand. That would be ideal so that you can inspect what you're getting.

 

[steven]

So I am having trouble locating an AOD 4wd output shaft, anyone have any suggestions?

 

[don4331]

Isn't 4R70W just a AOD with more electronics? Which would allow you to broaden your search.

But as noted at beginning - output shaft is 1st component in case; very few sellers are going to pull transmission completely apart just to sell you the 4wd output. You might find someone on one of the Ranger forum (this isn't only one, just the best) who converted Explorer 4W70 4wd transmission to 2wd, but you're looking for needle in haystack.​

 

[steven]

Anyone ever try these eBay radiators on V8 swap?

3 Row Radiator For 1991-1994 Ford Explorer Bronco II 4.0L/ 1985-94 Ford Ranger | eBay

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[steven]

So ordered adapter to retain ranger tcase, got cam, explorer heads and intake on motor and just about ready to pull it out of mustang.