How-To: Convert Your Auto 4WD to a Manual 4WD, Redneckstyle

This is NOT my How-To, I found this on another forum, and thought it was a cool idea, but really cheesy.

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Here is how I converted an electric shift transfer case to manual. There are expensive ($300+) inside lever conversion kits, the "shiftster" **** if you don't mind crawling under the vehicle every time to shift, and some other clumsy do-it-yourself ideas using speedometer cable or a right angle drill attachment to rig-up an inside manual shift mentioned on the internet. I wanted a simple, reversible inside the vehicle method, and came up with using a piece of 3/8" iron pipe nipple, a chunk of old hydraulic hose, two hose clamps, and a piece of 3/8" bolt. I took the pipe nipple, and hammered one end into a triangular shape to fit over the triangular shaped shaft sticking out of the t-case after you remove the electric shift motor. I made a triangular shaped bolt to use as a mandrel by grinding a 3/8" bolt to match the corresponding triangular shaped hole in the shift motor, and then used this bolt to help me make one end of the pipe nipple the right shape. I then drilled, tapped and used a short bolt to use as a set screw to help hold the nipple on the t-case shaft. I then bent a 3/8" bolt into an "L" shape to use as a handle to help turn the hose to shift (you could get away without this, as the hose turns readily, but a handle gives you a visual reference of where the hose is turned). I then drilled a hole in the floor board just behind the drivers seat that best lines-up with the shaft on the t-case. I then installed the nipple on the t-case shaft, retaining it with the set screw. I then fed the hose through the floor-board hole, and fit over the other end of the nipple and tightened down with a hose clamp. I lined up the hose clamp screw head with the markings on the t-case to show where the t-case was engaged (2WD, 4WD, or 4WDlow) so I would know at a glance where the t-case was currently set). I inserted the "L" shaped bolt into the other end of the hose, and retained it with the other hose clamp. That's it! To shift, you simply turn the "L" handle from inside the vehicle. All the way counterclockwise is 2WD, turning the "L" handle 90 degrees clockwise to the first felt stop is 4WDhigh, and all the way clockwise is 4WDlow (you still have to be stopped, in neutral, with your foot on the break to shift in or out of 4WDlow). I used hydraulic hose, as it will not collapse on itself under the torque pressure, but will still bend to line-up with the shaft on the t-case as you turn the "L" handle. I tuck the handle end of the hose under the front seat middle seat belt holder bolted to the floor behind the driver's seat when not shifting, which helps "lock" the hose from turning when you don't want it to (and keeps it out of the way also). Here are some pictures to better explain the idea.
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What i want to know is what expensive kit is he talking about when he says "There are expensive ($300+) inside lever conversion kits.."?????

And leaving your t-case open and exposed like that seems really stupid!!

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1999 Ranger 3.0FFV-ExtCab-4x4-My 99 Build
1998 Ranger 3.0-ExtCab-4x4-PROJECT TRUCK-My 98 Build

The idea is genius, but the way he did it is completely stupid lol

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2000 XLT 4x4 EXT. CAB 4.0/Auto Trans/3.73 gears/
31x10.50 BFG Rugged Terrains on MB Motoring Wheels/Pioneer Head Unit/JBL 12"/Camo Interior/'03 black and grey 60/40 seats/ green LED's Under Dash/T-Bar Crank/Windows-20% on the front, 5% on the back/Mustang Dome Light/06 Tails/

Yeah i know...lol...I would have actually rigged up a stick shifter and some linkage, make it look professional...

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1999 Ranger 3.0FFV-ExtCab-4x4-My 99 Build
1998 Ranger 3.0-ExtCab-4x4-PROJECT TRUCK-My 98 Build

Yeah you could take a shifter out of any ford truck and make it look so much better

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2000 XLT 4x4 EXT. CAB 4.0/Auto Trans/3.73 gears/
31x10.50 BFG Rugged Terrains on MB Motoring Wheels/Pioneer Head Unit/JBL 12"/Camo Interior/'03 black and grey 60/40 seats/ green LED's Under Dash/T-Bar Crank/Windows-20% on the front, 5% on the back/Mustang Dome Light/06 Tails/

Are you sure that you turn it clockwise? 1999 Ranger

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1999, Red, 78K miles, 81 yy, into computers!
http://kensstuff.blogspot.com/

Maybe he'll make a little revision to the linkage.......after he's going down an arterial at 45MPH and misses 4H and finds 4L.

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2004 Ranger FX4 Level II, 5R55E, Sonic Blue Pearl

Proudly JAP/RICE free since March 2000

Couldn't you just drop the transfer case, and put a manual case in there? I know manual cases ain't cheap, but its better than rigging up something...

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BUILD THREAD: http://www.fordrangerforum.com/proje...-progress.html

Depending on the year you might also have to replace the computer... I knew a guy that had a problem with that when he switched from Auto to Manual.

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2008 XLT 4x4 - GRABBER ORANGE - 4.0 V6 - 5 spd
PNW CREW

I'll have to keep that in mind. I have shift on the fly, and HATE it. My tcase motor went bad, so I've been thinking about getting a manual tcase, but I didnt know about swapping computers

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BUILD THREAD: http://www.fordrangerforum.com/proje...-progress.html

The only reason I could see why the computer could get messed up is if senses the motor is missing. As even then, I'm not too sure if it would affect that. Both transfer cases in rangers are BW1354. The BW1354 comes from the factory so it can be used in a manual or electrical setup. The only thing I'm aware of that the computer receives from the transfer case is whether or not it's in 4x4, and weather or not to calibrate the speedometer. You can most likely convert your electric T case to manual if you find the correct shift linkages for it. There should be a plugged hole on the side if the transfer case somewhere or something of the such where the linkage for the manual lever connects to.

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