Has anyone converted a full time, single speed, AWD into a switched 4-hi/4-low 4x4 system on an Explorer? My AWD is shot and needs replaced, the more I read about the AWD vs true 4x4 I'd like to convert it if it's possible.

03 Explorer Eddie Bauer
4.6L V8
Full time AWD

 

I think the systems are entirely different.. Your "AWD" that is shot is in the transmission / transfer case ? A "true" 4 x 4 would have the front end engagement in the front axle or hub area.

 

You would need a new transfer case and probably new driveshafts. The transfer case is what sits behind the transmission and splits the power to the rear and front. Since it's computer controlled on your truck, it may need a new module, switch and harness to make it work properly, or you can use a manual case. If you go that route, though, the computer may not be happy.

 

Unless you need low range, you wouldn't gain much from the selectable 4x4 in other Explorers. Those systems run with an "Auto" setting as the default, so you always have 4 wheel drive on call, pretty much just as your AWD system does. I don't know how the AWD system splits the torque in "normal" driving, so it might be very different from the "Auto" setting mechanically, but in practice, it works almost the same. AWD being smoother than the engagement in Auto 4x4.

I thought I saw a recent AWD to 4x4 swap thread. I found one for the prior generation Ex on another site, but it's quite an undertaking:

Convert V8 AWD to BW 4406 Manual Shift- A how to thread - Ford Explorer and Ranger Forums "Serious Explorations"®

I'll try to find that other one.

 

Not the one I wanted, but an good comparison of AWD vs 4x4 in your vehicle:

https://www.ford-trucks.com/forums/1...wd-vs-4x4.html

 

yes the transfer case is the problem, the viscous clutch has gone bad. I saw the manual swap for the pre 2000 Explorers. I was hoping it would be a simple swap but it doesn't look to be the case. Ah well..

 

Have you done this yet. I have had a 94 and have lots of info.it can be done. I turned my van into a vw camper including over sizetires. To much to list here email me at icuff4cash@gmail.com or look up aerobomber on internet and aerostar fourm

 

Found you on "Serious Explorations" (explorerforum.com) as Icuff4cash. I'd like the 5.0 in my 98 Explorer too, already have the 4x4 and vastly prefer it to AWD, It is better in snow >2 in. But then there is $$ involved and my Explorer doing ok as is. Will be watching to see if OP ends up converting.