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Idahome
Joined: Wed May 2nd, 2018
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First things first, we had a transfer case debacle, now back on track:
Long story short the 4406 transfer case that came with this truck was sourced from a wrecker, they sold him the wrong case.
This unit is Torque on demand (control trac awd) and I did not notice until after it was hung......... I was working on changing the shift motor when I saw the extra sensors in the case. My heart sank a little....then I did a few days of reading about the control trac TOD 4406. Discovered I could build a stand alone AWD control box using either 6 automotive relays or better yet a home made printed circuit board control box dealio...some guys on the explorer forum have sorted out how to make the control trac AWD work in a non control trac truck using stock expedition parts!! Build a control trac ranger?? Seemed like a cool option....but also very custom, so we decided to skip it and use a real 4406 e shift case without the control trac
So last night I dropped the case back out and began to prep the non control trac 4406 I have.... this one is now on a shelf to be used as a boat anchor or possibly a AWD project down the road! would be cool for ice racing, or just plain icy roads....and now we are smarter for it, knowing what is possible with control trac sheesh
Now for the progress:
truck was put on the lift so I can tackle the 4x4, exhaust, and driveshafts
First up the stock 5.0 downpipes needed to go in. The parts I was given (came with truck) were cut tooooooo short so I had to source some stock downpipes
here you can see the pipes I was gives vs what is needed
I like to use full length stock pipes because they give you bolt up flanges so the exhaust can still be unbolted like stock. Also they utilize the stock 5.0 exhaust mount at the trans crossmember, this is needed for strength. The stock downpipes also include the primary cat converters and all 4 02 sensor bungs.....plug in like stock.
Here is a shot of the inside of the TMH collector Junglejoe was talking about earlier..... its so nice it looks like jewelry..
The stock downpipes were wiggled into place and hung using the super sweet locking head bolts Robert provided with the TMH. Anti seize was used and one bolt needed to have its head shaved down a bit to more easily clear the trans dipstick
the bolt before
bench grinder
Now it clears, yes I need new gloves
pass pipe put in place first then drivers, like playing tetris
Now with the downpipes in place its time to prep and hang the 4406 t case
First there are 2 "ears" on the 4406 that can be shaved off to help clear the ranger frame rails, sawzall or grinder makes quick work of these
Nice and smooth so we do not cut our skin later
T case was cleaned and gasket surface prepped, t case put on trans jack for easy install
tailhousing cleaned
one gasket and 6 bolts later the t case is in!!
Now time to swap shift motors, the stock 2000 Ranger motor will work perfectly. So we removed the motor from the ranger case and the 4406
Here's where I realized we had a TOD case!! SOB!!!!!!
stock downpipes in place
I will be cutting the needed exhaust flanges out of a 5.0 donor truck today as well as grabbing the 5.0 trans/ exhaust mount
all factory brackets are used here to hold the wiring, just like stock
So this transfer case is now on the ground and a true 4406e (no TOD!) is almost ready to go in
New tailhousing seal is on order....Im working on modifying a f1560 front driveshaft to fit and finding the correct rear driveshaft for this build.
While that is happening the remaining exhaust was cut out of the truck, a nice Gibson muffler.
The truck came with a Borla dual 2.5" inlet single 3" outlet muffler we will be using. I will build the pipes to connect this to the stock 5.0 downpipes
Time to focus on the rear axle........we are ditching the stock ranger unit for a freshly built explorer 8.8 with goodies......
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I build custom RBV, specializing in drivetrain conversions, wiring, suspension and complete custom trucks