Well i just finished swapping a 2000 ford explorer 5. So i went to napa and bought them, which they have instock with the conversion kit. Ford aod transmission installation and swapping guide by. Page 157 tires, wheels and loading power is supplied to all four wheels through a transfer case or power transfer unit. I would rather increase the mileage of the vehicle when 4wd is not necessary. How do you convert a 2002 ford explorer awd with transfer. I had a local ford ranger enthusiast help me convert my electronic transfer case to a manual when my transmission and transfer case both w. Get discount prices, fast shipping and ultimate product help when shopping for 2005 ford explorer sport trac parts at 4 wheel parts. The following gearboxes rank among the most requested and constitute one of the greatest upgrades one can make to a jeep. He did the swap with an electric case from an expedition.
Borg warner transfer case electric to manual shift. The transfer case has a 25 spline input sleeve, thus requiring a transmission to have a 25 spline output shaft. The borg warner part time transfer case was utilized by ford motor company in 1995 to 1999 in the explorer. When bolting a transmission up to this transfer case, the output shaft of the transmission assembly should extend approximately. Made from a solid 6061 aluminum block, the behemoth colossus case is lighter and stronger than a stock dana 300 housing. This 3piece aluminum part time transfer case can be easily identified by the splined receiver on the front that takes a.
Bw56 electric to manual transfer case conversion brackets. The ford dana 20 transfer case is gear driven with a cast iron case. Unless youre driving a ford super duty f250 f350 or something really old, you likely have a switch on your dash to activate your 4wd. Get discount prices, fast shipping and ultimate product help when shopping for parts at 4 wheel parts. Ford explorer 4wd with manual shift transfer case with borg warner 54 series transfer case 1991, remanufactured transfer case assembly by dahmer powertrain. Electronic transfer case no more, convert it to manual. It was used in early broncos from 1966 until 1977 and it was used in some ford pickups. Ford has always had a very modular approach to model diversification. I still want the ability to have 4wd low and high, i just do not want to have awd. The transfer case can either be shifted manually, or by a dash mounted selector switch. Explorer bw56f full size bronco, 198796 mediumduty, magnesium case, manual and electric shift f150, 250.
Converting electronically shifted tcase to manual shift. The bw 4411 transfer case is an automatic full time style of transfer case, available with both manual and electric shift variants. In 2001 rangers started judging speed with a vss in the tailshaft housing. Np203 transfer case illustration exploded view is provided to assist you in identifying parts and assembly sequence details. Explorer awd t case to 4406 conversion f150online forums. Threaded bosses are present on the trans case, a plate gets unbolted from the floor, bolts right in. Your transmission, transfer case and differential drivetrain. The 28 spline atlas was designed to fit only the 196677 broncos. I went on the forum and everyone said to switch to manual hubs. Ford explorer 4wd awd with electric shift transfer case with manual shift transfer case 1997, transfer case rebuild kit by skf. Transfer case 1993 ford explorer manual shift 127k miles 4x4 4wd fits. Ford bw54 transfer cases, borg warner 54 transfercase.
The dash switch works by sending power to an electric transfer case shift motor, that shifts the transfer case for you. Our rebuilt dana 20 transfer cases are built inhouse by our highly trained technicians. Make sure that all the components used in the wiring and switch are rated for at least 10a to be safe. Procedure spindle nut upgrade ford explorer 2wd 4wd conversion 1991. It became available as an electronic shift from 19861990. Weve recreated the brackets that ford no longer sells and are hard to find at the wrecking yards. My question is, can you swap a manual transfer case for the electric one, and if so what. Control trac transfer case modification brown wire. Ford explorer transfer were cases utilized the following transfer case models. Will not fit 87early 88 model vehicles, flange mount.
Explorer manual hubs atlas ii transfer case in ford explorer kkm air. Ford locking hubs and conversion kits ron the parts guy. From 19911994 the ford explorer platform came with a full ladder type frame based on the tough ford ranger platform, an extremely tough 8. Cut the long stem for the eshift shaft off inside the case, you cant miss it. Mile marker 449ss stainless steel dana 5060 locking hubs buy at amazon. Transfer case for 6677 ford broncos toms bronco parts. If you converted to an actual manual transfer case and got an older tailshaft housing for the mounts of the manual shifter, it will not have a hole for the speed sensor, and the only tailshaft housing you can use that has those would be a 02 or 03 level 2 housing. Or purchase this nos oem ford ranger explorer bronco ii transfer case shift motor. Please call 18888242012 before ordering to verify availability. Manual operation bw 54 electric transfer case ford explorer ranger enthusiasts serious explorations i believe dumperdave has a 54 manaul tcase for sale as well.
Electric to manual transfer case conversion ford f150 forum. Print, read or download a pdf or browse an easy, online, clickable version. Summit racing equipment carries cableactuated, electrical, and vacuumelectrical kits from 4x4 posilok, alloy usa, rt offroad, and bd diesel, plus permlok central axle disconnect locking systems from 4x4 posilok. We offer the highest quality professional rebuilt transfer case parts and rebuild parts kits that are designed to be top of the line overhaul kits.
View and download ford explorer 1997 owners manual online. If you have a electonic switch to change from 2wd to 4wd even with. I worked at ford in powertrain development on the ranger explorer platform for a number of years and we regularly swapped the hub sets as needed to match the transfer case manual or electric. The transfer case contains a transfer case clutch coil, which is what locks the front and rear driveshafts together.
Our products have been featured on gas monkey garage, overhaulin, spike tv, discovery channel, and much more. Bw50f bronco ii, ranger, 198389 lightduty, magnesium case. This was convenient, though ford did recommend changing back to twowheel operation by first stopping the vehicle, then backing up a few feet, this to fully disengage the fourwheel drive. Fullsize ford truck transfer cases blue oval trucks. Before you begin, a few items should be taken into consideration. We supply topquality transfer cases, case halves and parts at affordable prices. Apparently the electric shift transfer case in my expy borg warner bw4406. Mile marker 449ss locking hub service kit dana 60 buy from amazon. Understanding the 4wd in your ford blue oval trucks. Transfer case motor 199912 f250 f350 f450 f550 super duty. Manual transfer case conversion ford explorer ford ranger. Most conversions are designed so that relocation of the transfer case can be avoided.
In about 5 minutes you can get rid of your junky electric motor and install a manual cable shifter. Electric shift t case manual shift conversion great lakes. All of our transmissions are dyno tested to ensure the highest quality standard possible. A more basic system with a floormounted transfer case lever and manual front hubs was available for credit. A handful of supreme transmissions have risen to the top of jeepers lists. Ford explorer, mercury mountaineer repair manual 20022010. Ford bw54 transfer cases, borg warner 54 transfercase, bw. Access quick reference guides, a roadside assistance card, a link to your vehicles warranty and supplemental information if available. The atlas has been designed to replace the stock borg warner 50 transfer case.
The best online destination and local store solution for all of your truck and jeep offroading needs. Has anyone done a conversion from a automatic button transfer case with that crappy electric motor to a manual transfer case. Buy online and pick up in store, or get fast, free delivery on qualified orders. As an option, the explorer was also offered with a manual shift transfer case the option was paired with manual locking hubs. The bw54 is a ford brand transfer case that comes with an aluminum transfer case and is chain driven. The most common transmission swap with older fords is from a c4, c6, or fmx to an aod or manual 5speed. Ford expedition 1998 workshop manual pdf download manualslib. Back to other model transfer case parts availability page, dont see what you need just give us a call toll free 8002161632. Bw45f f250 198092 magnesium case, mediumduty, manually shifted transfer case. Swaping in a manual transfer case rangerforums the ultimate. I cannot verify the accuracy of the data presented, so please do some additional research prior to spending timemoney on a conversion.
Find your owner manual, warranty here, and other information here. I wanted to post this to put some more information out there in the ford ranger world. Nov 26, 20 here is how i converted an electric shift transfer case to manual. This is only the bracket that ford no longer makes. Information on transfer case operation and shifting procedures can be found in the driving chapter. The nimrods at ford have a vss sensor in the tailshaft but, when you remove it there is no tone ring inside. Borg warner transfer case electric to manual shift conversion. This product is made of highquality materials to serve you. Hello, ive acquired a nice 87 ranger 4x4 with 4 cyl, 4 speed and manual. Check tag located on rear of unit for model number. The np203 transfer case was used by dodge from 19741979, ford from 1974 to 1979 and chevrolet and gmc from 1973 to 1979. Is it possible that the transfer case is gummed up and causing my shift motor. The np203 transfer case is a chain driven transfer case with a cast iron case. Do not listen to the man above me, i have a 94 lifted explorer with 6 inches of lift, after my hubs broke the first time which are complete garbage from ford.
These pumps are known to spin either from the case or the pump wearing out. New 1978 ford bronco 197678 ford f150, f250, f350 ujoints size 4 caps dim. Ford explorer 1997 owners manual pdf download manualslib. If you are going to run a manual shift transfer case like me make sure you relocate the main gray plug on the metal bracket on the transmission forwards. Ford explorer transfer case best transfer case parts for. Normally this isnt an issue, but i was needing to pull some trees around after felling them and didnt want to burn out my clutch. When replacing automatic 3 hole cap screw hubs with manual hubs, you must purchase corresponding spindle nut conversion kit per application chart j. Vehicles with fulltime 4wd will require a transfer case conversion kit h. You depend on it to get the job done and the performance, comfort and style are well worth the investment. How do you convert a 2002 ford explorer awd with transfer case and neutral tow to either a fwd or rwd unit with transfer case and neutral tow. Electric shift t case manual shift conversion great. Transfer case np203 rebuild kits drawing and parts list. It is drivers drop and it was available with a couple different low range ratios. Improve your 4x4 truck or suvs reliability and increase your control with manual front axle engagement systems.
Found a manual transfer case on craigslist its s 54 out of a 96 ranger. View and download ford expedition 1998 workshop manual online. In some cases, slight modifications to the mounting brackets andor shifter handles are required. It can be found in ford vehicle applications such as the nonsport explorer from 2002 and up. I have a 93 explorer with the electric push button 4x4, borg warner 54. The adapters we offer are compatible with both styles transfer case shifter linkages. I drilled a hole in the bracket and mounted it to the first hole. Other powertrain explorer awd t case to 4406 conversion hey there, i am new here but not to this stuff. Apr 11, 20 last fall my electronic transfer case decided not to allow me into 4low. I used a bw4406 manual shift transfer case out of a 2003 f150. The bolt pattern on the face of the dana 20 is a 6bolt hex pattern, which we mirror on the atlas transfer case. So far i have a 2001 f150 manual shift 4406 t case with 7 miles on it.
We provide the necessary mounting holes in relatively the same location on all of our adapters. An illustrated drawing is provide below to assist you in parts identification, ordering and assembly. All specifications, performance and fuel economy data of ford explorer 4wd 4. Bw54, bw4403, bw4404, bw4405, bw4410, bw4411, bw4412 and bw4414. The borg warner bw4406 is a full time, chain drive is supplied in both manual and electric shift transfer case versions. Last fall my electronic transfer case decided not to allow me into 4low. Designed utilizing the latest technology, this product by skf features premium quality and will perform. Ford rangerexplorer manual transfer case conversion the. Electric transfer case to manual transfer case swap the ranger. The stock transmissions used in these vehicles were normally coupled to a dana 20 transfer case. This does not turn your electric shift transfer case into a manual shift. This transfer case has been manufactured in both a manual shift and an electric shift style.
There are two small bolts that hold the bracket on. Add to that nearly endless clocking, builtin twinstick shift mechanism, and the ability to be assembled either right or left hand drop, and you have one answer to all your transfer case. Advanced adapters atlas ii transfer case ford explorer. Located at 11071 93rd avenue n suite a maple grove, mn 55369. Ive always hated the electronically activated portion of my 4wd system, so i decided to get rid of it. You should first consider clearance for the atlas case. The bw50 manual shift transfer case was offered in the ford ranger 4. The focus here is putting a ford aod into a classic mustang and other vintage ford applications, which are the more common swaps. A cross reference table is provided below to aid you in identification of your transfer case.
724 685 849 783 817 1501 1324 1126 671 903 1483 855 273 1024 108 701 824 349 277 464 710 480 887 413 722 1168 870 179 1056 480 769 519 739 1052 48 789 1271 633