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I have a 96 F150 in decent shape thats 2wd, automatic and a 92 F150 4wd 4 speed that is trashed body wise. I am entertaining the idea of putting the 4wd on the 96. My question is, will the ecm cooperate with the 4 speed in place of the automatic, or will i have issues with the electronics. Both are 302, and 3.55 gears.
Well first I'd say check your 92. That should have a 5 speed. You are two 2 swaps here then, a 4wd conversion and a auto to manual conversion.
Basically you will need the manual tranny and all associated parts. For the ECM, just switch it out with an ECM for a manual trans truck. Too easy. Also you MAY be able to swap most of the lower wiring harness to retain full stock functionality, but im not sure since your going OBD1 to OBD 2.
The 96 is OBD2 so you won't be able to just swap ECUs. You will need an ECU from a 96 with manual trans. You will also need the lower wiring harness from a 96 manual trans truck since your 96 will have 4 O2 sensors and the 92 only has 1. You can use your existing harness but you will need to modify it to work with the manual trans reverse lights and also jumper the neutral safety switch.
I have used an auto ECU with a manual trans and it's OK to do that but that is with OBD1. I am not sure if it will work on OBD2.
I say change the output shaft, get a ext housing, unplug the short wiring harness off the 96, take the transfer case off the 96, and I'd get a Dana 44 solid axle and slap it all under the 92, with a 6" lift and 35-37's.
If your gonna go through the trouble of a SAS might as well use a d60.
Like Chris mentioned. 37s on a d44 TTB or solid. You're gonna break something unless you really upgrade the shafts and gears. 35s are fine unless you do heavy duty rock crawling or jumping.
I don't have any problems outa my Dana 44, I run 35's. Main reason I said 37's was some people like a bigger tire with the 6" lift. But, yall are right, you could always do a Dana 60 since a SAS is predy much a SAS.
If you do a SAS Dana 60, look at getting a 10.25 rear.
The simpliest and eaiest thing to do, if you just want 4x4 and no lifts or hard off roading, is just to unbolt the Dana 44 from under the 96 and bolt it under the 92.
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