Electronic 4x4 to manual 4x4 swap...possible?
03-15-2010, 09:34 PM
#1
Yooper
Thread Starter
Electronic 4x4 to manual 4x4 swap...possible?
Would really like to get rid of my electronic twist on the fly 4x4 to manual on the floor 4x4. I know they make a plunger to lock in the front diff from inside the truck but how would I change the transfer case to manual 4x4? Any one make the swap?
03-17-2010, 12:25 AM
#4
Yooper
Thread Starter
I'm guessing all I would need is the manual 4x4 transfer case, front diff plunger and all the linkage and hardware for the t-case. Someone has to have made the swap.
03-17-2010, 04:47 PM
#5
Member
1) Buy both manual transfer case selector and matching transfer case from the salvage yard/e-bay/www.car-part.com
2) Buy only the manual transfer case selector and needed levers and brackets for the transfer case from the salvage yard/e-bay/www.car-part.com
Either way, your hubs and differential are electonically and vacuum engaged. You will need to find your signal wire on the back of your dash switch. This switch is what signals the solenoid that engages your transfer case range and front differential solenoid that locks your hubs and differential. It would be best to have a manual t-case for reference when it comes time to hook up your selector, levers, brackets if you did not buy a manual t-case.
The manual selector uses a bypass solenoid from the t-case that sends the voltage to the diff/hub solenoid/plunger. You will have 5-6 wires from your dash switch. 1 is direct power, 1 is direct ground, 1 is the signal wire for the t-case 2wd, 1 is the signal wire for the t-case 4wd H, 1 is the signal wire for 4wd L, and 1 is for the 4wd light in your instrument cluster.
You will need to remove the carpet or vinyl lining from your floor board which means the seat(s) will also need to be removed. Once the carpet/vinyl is removed you will see the templete stamped into the floorboard for the manual selector. You will need a sawzall or air saw to cut out the pass through, and a drill to drill out the mounting holes. The mounting holes will also be slighthly indented in the floorboard. All truck cabs are made with 5 speed templets and manual selector templets stamped into the metal. If the vehicle is an automatic transmission and dash switch 4wd they simply leave the templet untouched. However, if it is a 5 speed and manual shift like mine, they cut out the templet.
You will need to hook up your 4wd light wire to the t-case solenoid, you will need to trace both the 4wd H and 4wd L wires as they should come to 1 single wire to engage your diff/hubs. The single wire is what you will need to run to the t-case solenoid. You will need to do the same with the 2wd signal wire, main power wire, and ground wire as well. This way when you manually select your range, it will engage or dis-engage your front diff/hubs and your 4wd light will activate and de-activate.
It sounds difficult, but all your really doing is moving your dash switch to the transfer case and using a manual lever to engage instead of a dial switch.
I have not made the swap, as mine has the manual floor selector. But i have worked on way way way too many of each at the dealership and there is absolutely no doubt that this can be converted. Good luck
2) Buy only the manual transfer case selector and needed levers and brackets for the transfer case from the salvage yard/e-bay/www.car-part.com
Either way, your hubs and differential are electonically and vacuum engaged. You will need to find your signal wire on the back of your dash switch. This switch is what signals the solenoid that engages your transfer case range and front differential solenoid that locks your hubs and differential. It would be best to have a manual t-case for reference when it comes time to hook up your selector, levers, brackets if you did not buy a manual t-case.
The manual selector uses a bypass solenoid from the t-case that sends the voltage to the diff/hub solenoid/plunger. You will have 5-6 wires from your dash switch. 1 is direct power, 1 is direct ground, 1 is the signal wire for the t-case 2wd, 1 is the signal wire for the t-case 4wd H, 1 is the signal wire for 4wd L, and 1 is for the 4wd light in your instrument cluster.
You will need to remove the carpet or vinyl lining from your floor board which means the seat(s) will also need to be removed. Once the carpet/vinyl is removed you will see the templete stamped into the floorboard for the manual selector. You will need a sawzall or air saw to cut out the pass through, and a drill to drill out the mounting holes. The mounting holes will also be slighthly indented in the floorboard. All truck cabs are made with 5 speed templets and manual selector templets stamped into the metal. If the vehicle is an automatic transmission and dash switch 4wd they simply leave the templet untouched. However, if it is a 5 speed and manual shift like mine, they cut out the templet.
You will need to hook up your 4wd light wire to the t-case solenoid, you will need to trace both the 4wd H and 4wd L wires as they should come to 1 single wire to engage your diff/hubs. The single wire is what you will need to run to the t-case solenoid. You will need to do the same with the 2wd signal wire, main power wire, and ground wire as well. This way when you manually select your range, it will engage or dis-engage your front diff/hubs and your 4wd light will activate and de-activate.
It sounds difficult, but all your really doing is moving your dash switch to the transfer case and using a manual lever to engage instead of a dial switch.
I have not made the swap, as mine has the manual floor selector. But i have worked on way way way too many of each at the dealership and there is absolutely no doubt that this can be converted. Good luck
Last edited by Crazy Cooter; 03-17-2010 at 05:03 PM.
03-17-2010, 06:07 PM
#6
Yooper
Thread Starter
This is what I would use to change the front diff to manual and eliminate the vacuum all together.
So basically all I would need is the shifter assembly, transfer case, cables, etc...
So basically all I would need is the shifter assembly, transfer case, cables, etc...
03-17-2010, 06:27 PM
#8
Yooper
Thread Starter
That picture shows everything needed to make the front diff lock in and out fully manual. Then getting the manual 4x4 transfer case, lever, brackets, cables, etc... would make it fully manual 4x4. As far as I know, then a bit of wiring would make your lights function as well.
03-18-2010, 01:49 AM
#9
I recently put that cable lock system on my 2002 f-150. It gets rid of the vaccum actuator and makes it a manual pull cable basically. Works great ounce you get it adjusted. I like it because quite a few times I needed low range, but needed to turn real sharp backing in trailers, so with it in 4x4 low without the cable pulled, it is 2wd low.
Thanks
Thanks
