trasfercase swap
Cargo Master
Joined: Feb 2011
Posts: 3,450
Likes: 13
From: Forest lake minnesota
I havent but cant imagine it would be to hard, you might need different length drive shafts. I would find the same truck as yours and take some measurments. And most of all when you do it take lots of pics and keep us posted on the swap. 
FTE Leadership Emeritus
Joined: Sep 2000
Posts: 23,174
Likes: 1,678
From: Stephensville WI
From what I have been told, the major difference is the shaft where your shift motor or lever attaches. A major engineering challenge in using the ESOF box without the shift motor is getting some sort of mechanical shift linkage attached to the shaft where the motor attached. There is nothing to bolt the lever or linkage in place.
Lead Driver
Joined: Sep 2007
Posts: 8,180
Likes: 669
From: Scio, OR
A couple of people have fabricated a lever to attach to the shaft. Then all you need is the floor shift lever out of a truck with a manual transfer case and the right length rod.
If you have the whole transfer case, it should just be a matter of taking out the original and putting in the replacement. Wiring for the indicator light is different and would be an issue, though. You'd have to find the indicator lights coming from the 4WD control module (or the GEM depending on the year), and patch them into the switch on the manual transfer case.
If you have the whole transfer case, it should just be a matter of taking out the original and putting in the replacement. Wiring for the indicator light is different and would be an issue, though. You'd have to find the indicator lights coming from the 4WD control module (or the GEM depending on the year), and patch them into the switch on the manual transfer case.
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dragonas964x4
1978 - 1996 Big Bronco
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Jul 30, 2007 04:26 PM
