2000 Excursion Manual Transfer Case Swap
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Freshman User
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2000 Excursion Manual Transfer Case Swap
I have a 2000 Excursion V10, and it currently has the stock electric-shift 273 transfer case. In the name of expedience, and the relatively high difficulty of troubleshooting the electrical issues that may be preventing my 4WD from working, I decided to take the "easy" way out, and convert to a manual transfer case. I purchased a used 271 from a 2000 F-250/AT, and I found the appropriate shifter on ebay. Based on my understanding, this should be the extent of parts that I need to purchase for this project. I've read that there is a plate where the t-case shifter goes, that pops out, making that part of the installation pretty simple
For those of you who have done this conversion, What else do I need to watch out for? I don't particularly care if the dash 4x4 indicator light(s) work, but it would be a nice bonus if they did. Living in western Wisconsin, I just need the 4WD to work.
For those of you who have done this conversion, What else do I need to watch out for? I don't particularly care if the dash 4x4 indicator light(s) work, but it would be a nice bonus if they did. Living in western Wisconsin, I just need the 4WD to work.
Lead Driver
Joined: Apr 2011
Posts: 8,259
Likes: 346
From: Northern California
On my previous Ex I just converted my 273 to a manual shift by removing the electric shift motor and building my own manual shifter. The main diffrence between the 271 and 273 is the manual shifter vs electric however the 273 also has synchros which allow you to shift into 4wd high range at any speed so it was a better T case for my use.
Building a manual shifter for my current Ex has been on my project list for years, heck I even have the hunk of aluminum for the shift arm in my door pocket. Lmao
Building a manual shifter for my current Ex has been on my project list for years, heck I even have the hunk of aluminum for the shift arm in my door pocket. Lmao
Fleet Mechanic
Joined: Jan 2017
Posts: 1,665
Likes: 180
I've wondered about converting the 273 to a manual shift for a while now.
OP, are you having an electrical issue for sure, or are your hubs not locking in automatically? Have you been able to verify that the electric motor is in fact not shifting? Seems that you're set on the conversion, but wanted to make sure the more common things were already checked: vac lines aren't cracked/broken/leaking, hubs are lubed/cleaned/operating properly.
OP, are you having an electrical issue for sure, or are your hubs not locking in automatically? Have you been able to verify that the electric motor is in fact not shifting? Seems that you're set on the conversion, but wanted to make sure the more common things were already checked: vac lines aren't cracked/broken/leaking, hubs are lubed/cleaned/operating properly.
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Freshman User
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I've wondered about converting the 273 to a manual shift for a while now.
OP, are you having an electrical issue for sure, or are your hubs not locking in automatically? Have you been able to verify that the electric motor is in fact not shifting? Seems that you're set on the conversion, but wanted to make sure the more common things were already checked: vac lines aren't cracked/broken/leaking, hubs are lubed/cleaned/operating properly.
OP, are you having an electrical issue for sure, or are your hubs not locking in automatically? Have you been able to verify that the electric motor is in fact not shifting? Seems that you're set on the conversion, but wanted to make sure the more common things were already checked: vac lines aren't cracked/broken/leaking, hubs are lubed/cleaned/operating properly.
In any case, I'll be doing the thing this weekend. I'll post back with updates. The shifter may not be here in time, but I can at least swap the t-case, install my Warn hubs, and test things out.
Mountain Pass
Joined: May 2016
Posts: 245
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On my previous Ex I just converted my 273 to a manual shift by removing the electric shift motor and building my own manual shifter. The main diffrence between the 271 and 273 is the manual shifter vs electric however the 273 also has synchros which allow you to shift into 4wd high range at any speed so it was a better T case for my use.
Building a manual shifter for my current Ex has been on my project list for years, heck I even have the hunk of aluminum for the shift arm in my door pocket. Lmao
Building a manual shifter for my current Ex has been on my project list for years, heck I even have the hunk of aluminum for the shift arm in my door pocket. Lmao
I was under the impression that if you have manual hubs (and they are engaged) you can still use the manual transfer case to switch into 4H at speed.
Lead Driver
Joined: Apr 2011
Posts: 8,259
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From: Northern California
there are no syncros in the 271 so unless you get lucky the gears are just going to grind.
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Completed most of the conversion today. It took right around 6 hours, working with one other guy, taking our time. The new shifter won't be here until Monday, but everything else is done, and it all works as expected. It all bolted up as expected, and the only thing that I can't hook up is the switch on top that illuminates the "4X4" light on the instrument panel. This is something I can live with, in the name of making the 4WD system as reliable as possible. The Warn premium locking hubs complete the package.
I also replaced a front bearing hub. The ABS sensor was setting trouble codes, so it was time to replace it. When I started it up, the ABS light was off for the first time since I bought the vehicle. Unfortunately, the first time I hit the brakes hard enough to lock up the wheels (it's snowing, so this was easy), all four brakes locked up, and the ABS light lit up once again. Now it's complaining about the rear axle sensor. I guess my work is never done.
I also replaced a front bearing hub. The ABS sensor was setting trouble codes, so it was time to replace it. When I started it up, the ABS light was off for the first time since I bought the vehicle. Unfortunately, the first time I hit the brakes hard enough to lock up the wheels (it's snowing, so this was easy), all four brakes locked up, and the ABS light lit up once again. Now it's complaining about the rear axle sensor. I guess my work is never done.
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Freshman User
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On my previous Ex I just converted my 273 to a manual shift by removing the electric shift motor and building my own manual shifter. The main diffrence between the 271 and 273 is the manual shifter vs electric however the 273 also has synchros which allow you to shift into 4wd high range at any speed so it was a better T case for my use.
I attempted to install my F-250-style shifter, and found what appears to be a heating duct under the carpet, right over the plate that covers the hole where the shifter comes through. I'd imagine Ford did this because they never intended to install a 271 in an Ex. I may have to notch this duct to complete the project. The shift lever seems like it might be too long for the Ex, but I won't know until I get the cover open, and actually try to fit it in there. In any case, I have 4WD now, by leaving the T-case in 4H, and using my hubs to go engage/disengage the front axle.
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Lead Driver
Joined: Apr 2011
Posts: 8,259
Likes: 346
From: Northern California
No welding, I made the shift arm center hole the shape of the the shaft and then clamped it on like motorcycle shifter, my shifter was cable actuated so I could mount it to the body and not the trans, that allowed me to mount it where I wanted and not mess with cutting the rear passanger compartment area heather vent.
Clamp was similar to something like this
.
Lead Driver
Joined: Apr 2011
Posts: 8,259
Likes: 346
From: Northern California
Lots of cable shifters on the market but since you first posted this I picked up some parts off a Jeep XJ in the junk yard to make me a cable shifter for my current Ex.
my old one was something like this.
Laughing Gas
Joined: Dec 2006
Posts: 1,008
Likes: 5
No welding, I made the shift arm center hole the shape of the the shaft and then clamped it on like motorcycle shifter, my shifter was cable actuated so I could mount it to the body and not the trans, that allowed me to mount it where I wanted and not mess with cutting the rear passanger compartment area heather vent.
Clamp was similar to something like this
.
We just got a foot of snow and I had to get towed by GM products... Twice... Within a mile of my own house. (And once by an F-150.)
I need 4x4 to work and I don't want to have to crawl under the truck to bang on a freakin' motor in a foot of snow every time I need to shift to 4x4.
Fleet Mechanic
Joined: Jan 2017
Posts: 1,665
Likes: 180
This one should work....and it almost looks like the one posted.
Cable shifter, not sure. I would think you'd want a solid shaft because shifting the case is a bit hard. If you have a local yard, that's where I'd look first. Otherwise, you can order one from Ford, which will cost a pretty penny. You might find one on ebay. The X has the hole in the floor pan with a cover on it, which is a direct fit for the same year range super duty.
EDIT: why not just leave it in 4WD High all the time while there's snow on the ground?
Cable shifter, not sure. I would think you'd want a solid shaft because shifting the case is a bit hard. If you have a local yard, that's where I'd look first. Otherwise, you can order one from Ford, which will cost a pretty penny. You might find one on ebay. The X has the hole in the floor pan with a cover on it, which is a direct fit for the same year range super duty.
EDIT: why not just leave it in 4WD High all the time while there's snow on the ground?
Last edited by EXSwap; Jan 4, 2022 at 08:43 AM. Reason: added info
Laughing Gas
Joined: Jun 2021
Posts: 983
Likes: 366
Following along as I'm interested as well. I like to keep the stronger NP273 case when I do a motor & trans swap , but want to be able to manually shift it. Hopefully there's an "off-the-shelf" or "tried-and true" solution out there somewhere.
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More Turbo
Joined: Sep 2015
Posts: 640
Likes: 282
From: Texas
I knew I had some Déjà vu on this.
https://www.ford-trucks.com/forums/8...l#post12973070
Manualizing the TC seems like a good idea, but I've yet to have any issue with the electric motor.
Saving this info for when it goes bad.
https://www.ford-trucks.com/forums/8...l#post12973070
Manualizing the TC seems like a good idea, but I've yet to have any issue with the electric motor.
Saving this info for when it goes bad.
Lead Driver
Joined: Apr 2011
Posts: 8,259
Likes: 346
From: Northern California
I knew I had some Déjà vu on this.
https://www.ford-trucks.com/forums/8...l#post12973070
Manualizing the TC seems like a good idea, but I've yet to have any issue with the electric motor.
Saving this info for when it goes bad.
https://www.ford-trucks.com/forums/8...l#post12973070
Manualizing the TC seems like a good idea, but I've yet to have any issue with the electric motor.
Saving this info for when it goes bad.