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Old Jul 16, 2020 | 04:21 PM
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Transfer case options

I have an 03 Aviator, that I would like to put a manual shift, part time 2 speed transfer case in. What are my options? What did they come in?
 
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Old Aug 12, 2020 | 08:34 PM
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It appears no such animal exist's
So I tore my spare 44-10 apart and it appears that if you remove the VC it becomes all wheel drive with an open center diff, so my thought was, to replace the VC with a sleeve, that could be locked into 4 hi by a lever, to unlocked into AWD. Any thoughts on my brainstorm?
 
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Old Aug 12, 2020 | 11:13 PM
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What engine do you have? Manual shift transfer cases in anything were getting pretty rare in 2003. I have seen people install manual transfer cases behind 5.0 Mountaineers and Explorers, but not anything with the 4.6. I'm guessing the odds would be more in your favor if you had the 4.6. And then there's always the issue of how to get the speedo/odo to work. That's one of the challenges of installing the manual transfer case in a pre-2k Mountaineer/Explorer.
 
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Old Aug 13, 2020 | 09:07 PM
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4.6L DOHC v8 engine with the crapy 5 speed auto, it has the transmission mount on the transfer case, so that in it's self is a challenge.
 
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Old Aug 13, 2020 | 10:56 PM
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Well, here's a thought that's worth every penny that you paid for it. More like some things to ponder. You'd probably have to blaze your own trail on this one. Do you have that pioneering spirit?

If the 4.6 was available in the F150 then shouldn't the F150 transmission interface with your engine? You might be able to grab a tranny and transfer case from an F150 and swap the whole kit and caboodle in. I suspect the electrical interfaces (speed sensors, solenoids, etc.) and associated controls will be the biggest challenge. What could possibly be wrong? Obviously, something like this could take quite a while to figure out on your own. The good old days of easy swaps are long gone. No guarantees of success are expressed or implied.

To see what you might be in for, check this out: https://www.explorerforum.com/forums...e-swap.194529/
and
https://www.explorerforum.com/forums...e-swap.416479/
 
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Old Sep 5, 2020 | 04:37 PM
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Originally Posted by Mikeman
Well, here's a thought that's worth every penny that you paid for it. More like some things to ponder. You'd probably have to blaze your own trail on this one. Do you have that pioneering spirit?

If the 4.6 was available in the F150 then shouldn't the F150 transmission interface with your engine? You might be able to grab a tranny and transfer case from an F150 and swap the whole kit and caboodle in. I suspect the electrical interfaces (speed sensors, solenoids, etc.) and associated controls will be the biggest challenge. What could possibly be wrong? Obviously, something like this could take quite a while to figure out on your own. The good old days of easy swaps are long gone. No guarantees of success are expressed or implied.

To see what you might be in for, check this out: https://www.explorerforum.com/forums...e-swap.194529/
and
https://www.explorerforum.com/forums...e-swap.416479/
I have a Ford Aerostar with a one ton tranny and T case riding on Bronco solid axles and 35" MT's with about a 22" lift, so a tranny T case swap would be cake. That being said I have two trannys to cook before I spend my time on that.
 
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Old Sep 5, 2020 | 04:42 PM
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So I have too many projects going right now, but I did pull the VC out of the aviator, and it drives just like my Jeep Commander with the NV140. So at this point I have only confirmed my thought that it's just an open diff with a coupler.

I have pulled the main shaft out of my parts case, and will drop that off at my machine shop on Tue, to get a quote for making the sliding sleeve. I will update a take pic's once I am to that point.
 
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