Ok, so just a question, what is the difference between a 2wd and 4wd AOD Transmission? I'm aware the 4wd came with a deep pan, but what are the other differences? Is it a matter of just pulling the tailhousing and bolting up the transfer case adapter, or does it require changing internal transmission parts?

The only reason I'm even considering it, is in my area, I'm finding it far easier to source a 2wd model.

 

The output shaft is different so no it's not a simple job to convert a 2wd to 4wd, the whole trans has to be dismantled to change that shaft.

 

Considering I'll be taking any transmission I get apart for inspection and reseal, how hard is it to swap the output shaft, and are they even available?

 

Really is no point disassembling and reassembling a used transmission. Labour is the most expensive part of a rebuild and such an inspection is just a few points shy of a full rebuild. New pan gasket and filter, plus converter seal and tailshaft seal are about as far as you can reasonably go.

Conanski already told you the entire transmission has to come apart to replace the output shaft. Shaft is quite common used, never tried to find a new one. It's not a difficult job, but it is demanding in that you had better know what you are doing before you make a big pile of transmission parts. Number 1 rule is make sure everything is spotless.

 

Well, if you are already disassembling it, tear the 4wd apart and take the shaft out of that one. Unfortunately, Ford isnt like gm in the regard that you cant just cut a few inches off of the shaft and be made to work.

 

Not sure, but I think this is a C6 to AOD swap? Output shaft will not be the same.

 

Yes, this would be a C6 to AOD swap. I've rebuilt enough C4's, C6's TH350/400's over the years, that I feel confident enough to take apart an AOD and swap whatever needs to be swapped/replaced as part of the inspection.