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My truck might end up needing a new motor after the plug blowing out of the head. See my other post. Instead of going stock, we might end up putting in the lightning motor. I know that the tranny is strong enough, but will the transfer case stand up to the power?
Tell me if I'm incorrect here, but the transfer case is only used when in 4 wheel drive which is a very small portion of the time, just becareful with it when it is in 4x4 mode.
I'm also putting on an Lightning ASM on my 04 expedition.
Mine has 2 wheel drive, awd, 4x4 high and 4x4 low all controlled by that little switch on the dash. Living in Phx unless pulling the boat out of a dirt ramp at Lake Powell always I'm always in 2 wheel drive.
I still think you are probably okay on the transfer case. I would imagine it senses slippage in order to apply more or less power to front wheels? If that is the case unless you're in the mud or snow and under the gun I wouldn't worry to much about it because most of your power will go to the rear wheels.
You might check with Mike Dunn at www.madenterprise.com he's really knowledgeable about this conversion and can also sell you the factory fuel upgrades/heat exchanger pretty cheap.
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