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Which Transfer Case Adapter?
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 Posted: Mon Dec 3rd, 2018 01:58 pm
ILivermore
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JAMMAN wrote:
Which part... bad idle or no 4wheel low?

Cats are not causing bad idle even if empty. The upstream O sensors are all you really "need" and they are before the cats. 5.0's do not idle bad unless there is something really wrong like a bigger than normal vacuum leak, or electrical malfunction.

I'd start looking for obvious stupid things being you evidently are sharper than average about doing things and figuring things out. Get it in the dark and spray some water on the motor while it is running, look for blue spark traces. Disconnect the power brake line and put your thumb over it. If it is loud you might not be able to hear the vacuum leak.

If you took the intake off while putting the motor in maybe you got a piece of crap under it or screwed one of the gaskets up.

Has to be something simple.

Both. I'm more concerned with the 4low issue. I'm sure the run ability issue can be fixed



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 Posted: Mon Dec 3rd, 2018 02:48 pm
410customs
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agree 5.0L are pretty simple to get them to run smoothly
If it runs like crap there will be codes in computer, unless it is plugs/wires or fuel pressure

It may need some drive cycles before the codes show up

The discussion I found about the low range issue, basically they said I cannot get low range either....but never came back to fix it

I can make your 4x4 work, we can ditch the factory system you have now and wire in a better system
The 02-04 motorolla 4x4 controller module can be wired into your truck very easily and bypass your factory GEM and 4x4controller.....

When I do a 4406e shift t case, or 1354e shift t case or control trac delete I use the 2002-2004 Ranger / Explorer motorolla 4x4 control module
This box can be wired into just about any vehicle and it will shift your 4x4 motor using your dash switch.

I have extra motorolla boxes, I collect them from the junk yards. They have wiring pigtails and I have the wiring information. There are about 10 wires total to hook up and it works between your 4x4 dash switch and your 4406e shift t case motor...........



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 Posted: Mon Dec 3rd, 2018 03:19 pm
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410customs wrote:
agree 5.0L are pretty simple to get them to run smoothly
If it runs like crap there will be codes in computer, unless it is plugs/wires or fuel pressure

It may need some drive cycles before the codes show up

The discussion I found about the low range issue, basically they said I cannot get low range either....but never came back to fix it

I can make your 4x4 work, we can ditch the factory system you have now and wire in a better system
The 02-04 motorolla 4x4 controller module can be wired into your truck very easily and bypass your factory GEM and 4x4controller.....

When I do a 4406e shift t case, or 1354e shift t case or control trac delete I use the 2002-2004 Ranger / Explorer motorolla 4x4 control module
This box can be wired into just about any vehicle and it will shift your 4x4 motor using your dash switch.

I have extra motorolla boxes, I collect them from the junk yards. They have wiring pigtails and I have the wiring information. There are about 10 wires total to hook up and it works between your 4x4 dash switch and your 4406e shift t case motor...........

How hard is it to wire in and install? And how much are the boxes?



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 Posted: Mon Dec 3rd, 2018 03:38 pm
ILivermore
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ILivermore wrote:
410customs wrote:

agree 5.0L are pretty simple to get them to run smoothly
If it runs like crap there will be codes in computer, unless it is plugs/wires or fuel pressure

It may need some drive cycles before the codes show up

The discussion I found about the low range issue, basically they said I cannot get low range either....but never came back to fix it

I can make your 4x4 work, we can ditch the factory system you have now and wire in a better system
The 02-04 motorolla 4x4 controller module can be wired into your truck very easily and bypass your factory GEM and 4x4controller.....

When I do a 4406e shift t case, or 1354e shift t case or control trac delete I use the 2002-2004 Ranger / Explorer motorolla 4x4 control module
This box can be wired into just about any vehicle and it will shift your 4x4 motor using your dash switch.

I have extra motorolla boxes, I collect them from the junk yards. They have wiring pigtails and I have the wiring information. There are about 10 wires total to hook up and it works between your 4x4 dash switch and your 4406e shift t case motor...........

How hard is it to wire in and install? And how much are the boxes?

Truck is a 2000 Ranger XLT 4x4 (live axle) 3.0L
Engine & trans donor: 2000 Explorer Limited AWD 5.0L
Transfer case donor: 1999 F-150 XLT 4x4 5.4L



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 Posted: Mon Dec 3rd, 2018 10:44 pm
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ILivermore wrote:
ILivermore wrote:

410customs wrote:


agree 5.0L are pretty simple to get them to run smoothly
If it runs like crap there will be codes in computer, unless it is plugs/wires or fuel pressure

It may need some drive cycles before the codes show up

The discussion I found about the low range issue, basically they said I cannot get low range either....but never came back to fix it

I can make your 4x4 work, we can ditch the factory system you have now and wire in a better system
The 02-04 motorolla 4x4 controller module can be wired into your truck very easily and bypass your factory GEM and 4x4controller.....

When I do a 4406e shift t case, or 1354e shift t case or control trac delete I use the 2002-2004 Ranger / Explorer motorolla 4x4 control module
This box can be wired into just about any vehicle and it will shift your 4x4 motor using your dash switch.

I have extra motorolla boxes, I collect them from the junk yards. They have wiring pigtails and I have the wiring information. There are about 10 wires total to hook up and it works between your 4x4 dash switch and your 4406e shift t case motor...........

How hard is it to wire in and install? And how much are the boxes?

Truck is a 2000 Ranger XLT 4x4 (live axle) 3.0L
Engine & trans donor: 2000 Explorer Limited AWD 5.0L
Transfer case donor: 1999 F-150 XLT 4x4 5.4L

Update: Transfer case went partially into four low after fiddling with it a bit. The transfer case motor got super hot and now the 4high light doesn't come on and the 4high range doesn't work



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 Posted: Mon Dec 3rd, 2018 11:12 pm
JAMMAN

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I'm wondering if the absolute position of the shift rod in the transfer case differs somewhat between the 1354 and 4406. The diagram is a little less than a great explanation.

The switches it shows in the bottom rectangle are actually in the motor. If the angular position the driver in the motor is in does not match the actuator shaft position for 4H, 4L or 2 then it will never know it is there or might overshoot. This could account for the warm motor it might be fighting itself.

I have a 1354 but have not dropped the change for the 4406 yet. From what I am reading here we need to figure out the shaft position in relation to the screw holes for both transfer cases.

I bet the position is different on the 2. Maybe not by much but enough to make it difficult?

This needs to be resolved, most of the threads I see with this swap they use the mechanical transfer case.



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 Posted: Mon Dec 3rd, 2018 11:14 pm
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JAMMAN wrote:
I'm wondering if the absolute position of the shift rod in the transfer case differs somewhat between the 1354 and 4406. The diagram is a little less than a great explanation.

The switches it shows in the bottom rectangle are actually in the motor. If the angular position the driver in the motor is in does not match the actuator shaft position for 4H, 4L or 2 then it will never know it is there or might overshoot. This could account for the warm motor it might be fighting itself.

I have a 1354 but have not dropped the change for the 4406 yet. From what I am reading here we need to figure out the shaft position in relation to the screw holes for both transfer cases.

I bet the position is different on the 2. Maybe not by much but enough to make it difficult?

This needs to be resolved, most of the threads I see with this swap they use the mechanical transfer case.

I might just have to cut my losses and put a 4406M in it. I now have a lifted truck with no 4WD.



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 Posted: Tue Dec 4th, 2018 01:45 am
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This is the absolute best thread on this I have ever seen:
https://www.explorerforum.com/forums/index.php?threads/getting-bw-1354-or-4406-or-other-elec-transfer-case-to-work.290109/

But it looks like your absolute best and quickest thing to do would be to throw the 4406 shift motor back on there and get a motorola box from 410, there seems to be enough of a difference in the shift positions to make people go to great lengths adjusting it.

Whatever you do if the 1354 motor got hot I wouldn't use it.



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 Posted: Tue Dec 4th, 2018 02:52 am
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Yikes. After reading through that thread it looks like I'm gonna have to put a 4406M in.



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 Posted: Tue Dec 4th, 2018 03:05 pm
410customs
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Just use the motorolla box!!! You have a junk yard near you right? You can find these boxes in several different Fords
All the wires you need are already in place in your truck

So it goes like this, 1986-1994 the trucks had a stand alone 4x4 control module (remember the little box under the dash with the white  button and little red light)

in 1995 they added some of the ESOF functions to the Gem module and a small 4x4control box. This system is a PITA!!

In 2002 they went back to a stand alone 4x4 Control module...the motorolla box

Same dash switch, same shift motor controls, GEM no longer involved

So you can get your system working by wiring in the motorolla box and possibly using the 4406e motor.

The shift motors are slightly adjustable for position, remember the hash marks on the armature top plate? You may be able to adjust your current motor until you get hi and low.........if that doesnt work then use the motorolla box and possibly the 4406e shift motor.

Ill dig up the  wiring info so you can see what is involved
I can ship you one of these boxes as well, I give my stepsons $40 for each one they bring me from the junk yards, so $40 plus shipping and its yours I have about 8 of them


Any 2002-2004 Ranger under the pass kick panel you will find the motorolla box and cut the wiring pigtails too.....also 2002-04 Explorers have them and several other fords..

Last edited on Tue Dec 4th, 2018 03:12 pm by 410customs



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 Posted: Tue Dec 4th, 2018 05:32 pm
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410customs wrote:
Just use the motorolla box!!! You have a junk yard near you right? You can find these boxes in several different Fords
All the wires you need are already in place in your truck

So it goes like this, 1986-1994 the trucks had a stand alone 4x4 control module (remember the little box under the dash with the white  button and little red light)

in 1995 they added some of the ESOF functions to the Gem module and a small 4x4control box. This system is a PITA!!

In 2002 they went back to a stand alone 4x4 Control module...the motorolla box

Same dash switch, same shift motor controls, GEM no longer involved

So you can get your system working by wiring in the motorolla box and possibly using the 4406e motor.

The shift motors are slightly adjustable for position, remember the hash marks on the armature top plate? You may be able to adjust your current motor until you get hi and low.........if that doesnt work then use the motorolla box and possibly the 4406e shift motor.

Ill dig up the  wiring info so you can see what is involved
I can ship you one of these boxes as well, I give my stepsons $40 for each one they bring me from the junk yards, so $40 plus shipping and its yours I have about 8 of them


Any 2002-2004 Ranger under the pass kick panel you will find the motorolla box and cut the wiring pigtails too.....also 2002-04 Explorers have them and several other fords..

I think i'm just gonna go with a manual case and get some reliability out of the system. Already have a 4406M case out of an '03 F-150 with 125K on it on the way for $175. Still trying to find the shifter assembly and how to make the lever work with a body lift. Also have to figure out how to wire the dash lights. Any insight on that?

Do you think I should go the manual route?

Last edited on Tue Dec 4th, 2018 05:37 pm by ILivermore



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 Posted: Tue Dec 4th, 2018 05:44 pm
410customs
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Yes
My old 96 Sploder I converted to the 4406m and I had a 3" body lift Lol

https://www.explorerforum.com/forums/index.php?threads/410fortune-96-awd-ex-goes-low-range.166605/ 

Shifter assembly can be a PITA to find
The reason is when the junk yards take apart a truck the transmission goes to one shelf and the t cases go to another

The linkage is mounted to the transmission
So what I did/do if I cannot find it at my local junk yards, I will go to the wrecker and explain to them what I am looking for and why, usually they will send me back to the shelf of transmissions with a guy and I will point out what I need
You need linkage off a 4r70w 4x4 transmission from a F150
AND the connector rod that goes from t case lever to the linkage

Let me see if I can find some part numbers for you

The body lift has little to no effect on you, in fact I usually cut down the F150 4x4 shift lever a few inches when we put these in explorers because they are too long, chop and weld... with the body lift the shift lever length is just about right
I used a shifter boot from a geo tracker in my 96, it worked perfectly.

Last edited on Tue Dec 4th, 2018 06:23 pm by 410customs



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 Posted: Tue Dec 4th, 2018 05:52 pm
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410customs wrote:
Yes
My old 96 Sploder I converted to the 4406m and I had a 3" body lift Lol

Shifter assembly can be a PITA to find
The reason is when the junk yards take apart a truck the transmission goes to one shelf and the t cases go to another

The linkage is mounted to the transmission
So what I did/do if I cannot find it at my local junk yards, I will go to the wrecker and explain to them what I am looking for and why, usually they will send me back to the shelf of transmissions with a guy and I will point out what I need
You need linkage off a 4r70w 4x4 transmission from a F150
AND the connector rod that goes from t case lever to the linkage

Let me see if I can find some part numbers for you

I'll have to double check that the transfer case they're sending me is out of a 4R70W truck



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 Posted: Tue Dec 4th, 2018 05:56 pm
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And I may lengthen the shifter some how. I'm a big dude and don't want to have to bend over to use it. Could run into issues because I have a full length console



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 Posted: Tue Dec 4th, 2018 06:26 pm
410customs
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you wont run into issues, explorers also have full console
Check out the pictures in the thread I posted from Explorerforum.... you can see my 96 explorer with 4406, details about the linkage, and the body lift

The 4406 doesnt care if it was behind a 4r70w/AODe,or not, they are all 30 spline input Ford 6 bolt t case pattern

In the larger trucks or F-150 with the 5.4L they used the E4OD/4r100 transmission and the 4407 t case......still a 30 spline input and 6 bolt pattern, but too large to fit a ranger.......



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 Posted: Tue Dec 4th, 2018 06:31 pm
410customs
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I found out how to make your 1354 motor work

There is a wire missing from your 5.0L V8 transmission wiring harness that the V6 trucks have:

In the V6 transmission harness there is a red/white wire, this is the neutral safety feed. On your V6 truck it goes through the C115 42 pin connector under your hood. On the V8 transmission wiring harness this wire is missing.
You need to add it (on the 5.0L side)
Then you need to make sure this wire goes into the Gem module, pin 22 on connector C282

Now you can use your 1354 shift motor to turn your 4406e case

I just spoke to a good friend of mine Brett who has done this conversion....he filled us in on the details

Last edited on Tue Dec 4th, 2018 06:35 pm by 410customs



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 Posted: Tue Dec 4th, 2018 06:31 pm
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410customs wrote:
you wont run into issues, explorers also have full console
Check out the pictures in the thread I posted from Explorerforum.... you can see my 96 explorer with 4406, details about the linkage, and the body lift

The 4406 doesnt care if it was behind a 4r70w/AODe,or not, they are all 30 spline input Ford 6 bolt t case pattern

In the larger trucks or F-150 with the 5.4L they used the E4OD/4r100 transmission and the 4407 t case......still a 30 spline input and 6 bolt pattern, but too large to fit a ranger.......

So its probably the shifters that are different between the 4R100 and 4R70W?



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 Posted: Tue Dec 4th, 2018 06:37 pm
410customs
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Yes shifters SLIGHTLY different, but a 4r100 shifter assembly can be made to work...

You can use the shifter assembly from a 1356, 4406, or 4407 t case...they all have the same shift pattern
The difference is in the length of the rod between shifter and t case..... I have had to build these a few times to make our setup work for different conversions...again I usually end up shortening or lengthening the parts we have in front of us with a grinder and a welder.....
The only one I KNOW will bolt onto your 5.0L transmission is the linkage from a 4.2 or 4.6L F150 with the  4r70w and 4406
The Gen III Explorer also uses a 4r70 behind the 4.6, but they never had a manual T case
Shifter/linkage can also come from a 5 speed truck

Last edited on Tue Dec 4th, 2018 06:40 pm by 410customs



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 Posted: Tue Dec 4th, 2018 06:38 pm
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410customs wrote:
I found out how to make your 1354 motor work

There is a wire missing from your 5.0L V8 transmission wiring harness that the V6 trucks have:

In the V6 transmission harness there is a red/white wire, this is the neutral safety feed. On your V6 truck it goes through the C115 42 pin connector under your hood. On the V8 transmission wiring harness this wire is missing.
You need to add it (on the 5.0L side)
Then you need to make sure this wire goes into the Gem module, pin 22 on connector C282

Now you can use your 1354 shift motor to turn your 4406e case

I just spoke to a good friend of mine Brett who has done this conversion....he filled us in on the details

Is the transfer case throw the same as the 1354? I read something on that yesterday



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 Posted: Tue Dec 4th, 2018 06:41 pm
410customs
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Yes 1354 motor will turn 4406
I am now in the know
Brett has done this more then once, Brett is my wrenching buddy we have done many conversions together...he also builds all of my auto transmissions. Brett goes WAAAAY back on this Ranger Explorer stuff
Brett has a 98 5.0L Eddie Bauer explorer he put together for his dad to daily drive. It is using the 4406e with the motorolla box and a 1354 wiring harness and shift motor

It makes sense we have to run a wire from the 5.0L transmission to the Gem Module for the neutral safety...no 5.0L trucks were ever built with ESOF 4wd so they never needed this wire

I was trying to get a hold of Brett about this since we started researching your issue....we finally texted back and forth this morning

Last edited on Tue Dec 4th, 2018 06:45 pm by 410customs



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 Posted: Tue Dec 4th, 2018 06:45 pm
ILivermore
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410customs wrote:
Yes 1354 motor will turn 4406
I am now in the know
Brett has done this more then once, Brett is my wrenching buddy we have done many conversions together...he also builds all of my auto transmissions. Brett goes WAAAAY back on this Ranger Explorer stuff
Brett has a 98 5.0L Eddie Bauer explorer he put together for his dad to daily drive. It is using the 4406e with the motorolla box and a 1354 wiring harness and shift motor

It makes sense we have to run a wire from the 5.0L transmission to the Gem Module for the neutral safety...no 5.0L trucks were ever built with ESOF 4wd so they never needed this wire

So thats all that needs to be done? That 1 wire? I'm assuming that 4low works because the truck doesn't need to be in neutral to shift it?



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 Posted: Tue Dec 4th, 2018 06:47 pm
410customs
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yes the wire is all that's needed

To get the shift motor to turn your t case into low range the Gem module must see that you are stopped (BOO circuit) and in Neutral (NSS circuit)



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 Posted: Tue Dec 4th, 2018 06:51 pm
ILivermore
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410customs wrote:
yes the wire is all that's needed

To get the shift motor to turn your t case into low range the Gem module must see that you are stopped (BOO circuit) and in Neutral (NSS circuit)

Only issue i'm running into now is those pins and connectors don't match on my truck



____________________
2000 Ford Ranger XLT 4x4
3" Performance Accessories Body Lift
4" Superlift Suspension Lift
Fox Racing Coilovers, Eibach Springs
Camburg Heim Inner Tie Rods
FR36S Leaf Springs
4.56 Yukon Gears
Much More
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 Posted: Tue Dec 4th, 2018 06:57 pm
ILivermore
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ILivermore wrote:
410customs wrote:

yes the wire is all that's needed

To get the shift motor to turn your t case into low range the Gem module must see that you are stopped (BOO circuit) and in Neutral (NSS circuit)

Only issue i'm running into now is those pins and connectors don't match on my truck

Are those connector numbers you're giving explorer numbers?



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2000 Ford Ranger XLT 4x4
3" Performance Accessories Body Lift
4" Superlift Suspension Lift
Fox Racing Coilovers, Eibach Springs
Camburg Heim Inner Tie Rods
FR36S Leaf Springs
4.56 Yukon Gears
Much More
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 Posted: Tue Dec 4th, 2018 07:02 pm
410customs
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I'm not sure , those were off the top of Brett's head. he is at work

C115 is the large 42 pin connector on your firewall all 96+ RBV have this

C282 is one of the connectors at the Gem module
Should be the same on all Rangers with gem module 98+?


Do you still have your V6 wiring harness?
What we are to do it unpin the neutral safety from your Rangers transmission to C115, and pin it in place in the 5.0 harness from trans to plug C115
Also check on the Ranger that this wire does indeed connect to the Gem module (continuity)

I can look up some wiring diagrams and trace this out I have a 2000 model wiring book downstairs.....

Last edited on Tue Dec 4th, 2018 07:04 pm by 410customs



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