I am looking for a 2002-2003 SD PSD with 4x4 with manual hubs and transfer case. I have been unable to find such an animal. All I can find are ESOF's. What are the odds that if I find a truck that has everything I want EXCEPT the 4x4 stuff, I can buy and convert it to a manual system????? Thanks, Aaron

 

I would just convert to an aftermarket manual hub (like Warn or Mile Marker). Leave your transfer case alone until you can find the right parts to convert to a manual case, if desired.

I know the ESOF shift motor can be problematic, but I thought the hubs were the worst part of the system?

 

Putting on Manual hubs will be the easy part. You'll have to get the shifter, linkage, trim pieces and etc. from a donor vechicle. (Preferably a low mileage Total) The hard part will be cutting the proper hole in the floor (Maybe there is one already?) and getting all the linkage to line up and work well. Its a chore but I am sure it can be done.

 

He'll also have to swap the transfer case. ESOF uses a different case than the MSOS trucks.

 

I didn't know that. That being the case I don't think its worth the trouble or the money. Best off just buying a truck with a manual set-up.

I do think your right about the hubs being the most problamatic. On both my dads 99' and 03' (Both w/ ESOF) the hubs and some seals were replaced several times under warrenty on each truck. I don't think they even touched the transfer case. His problems is what made me get a manual 4x4 on my truck.

 

My hubs started acting up 1 and a half years after purchase. I diagnosed it as the hubs themselves not latching all the time.

Out they went, in went Warns.

I still have the **** on the dash, and I do use it a few times a month, and almost 100% in the winter if there's snow on the local residential roads.

If I were going somewhere remote where I really need 4x4 to survive, I'd have a spare servo in the glovebox. Also, it is possible to manually engage the 4x4 if you remove the servo. I ALWAYS engage 4x4 BEFORE I get even close to needing it, just to make sure it works. I don't go into the woods in 4x2 until I get stuck and then try to get into 4x4

I will say, if and when my transfer case ever blows up, I WILL be swapping in a manual case.

 

The difference in the transfer cases is the ESOF case does not have a neutral position. Because of this I don't think the manual shifter would work properly.

It might work, I just don't know of anyone who has done it.

 

This is probably a dumb question.. but if you put in manual hubs, does it make the switch on the dash useless? If so, how do you shift into 4 low?

 

There is a link in the TECH FOLDER on how to change your hubs to MANUAL. Check it out, it is very well done.

The dashboard switch will still control your transfer case. What would happen is that if you think you might need 4x4 you turn the hubs to LOCK. When you need 4 wheel drive you would flick the dash switch and 4 wheel drive would engage.

The trick is to lock the hubs if you think you might need 4 wheel drive. It isn't a real big deal, owners with manual systems have been doing it for decades. It doesn't hurt anything to run with the hubs locked and the trasfer case in 2 wheel drive.

 

Thanks Redford.. I know when I had a vacuum problem a few months back I had to manually lock em up get into 4wd. I do want to upgrade to the Warn hubs.

 

I've tried to open this link several times and only get an error message. This link is dead.

 

Well rat farts

 

That dead link is completely MY FAULT!

He sent me the document by email back in May, and I never got around to putting it somewhere.

Here's a link to it, but don't bookmark it - I'll change the one in the tech folder - eventually.

Super Duty Automatic to Manual Hub Conversion.doc