I need to install a 2wd 4r100 into a 4wd drive truck. 02 into a 01 . both are 5.4s. I have to switch the tail housing and also the output shaft so that the tranny will mate up to the transfer case.
I have been told this will involve a teardown of the trannies to remove output shafts.
Can anyone confirm or dispute this? Anyone done it before?
I'm just trying to get all my ducks in a row before I start busting my knuckles and swearing.
Ok Thanks, Do you have any suggestions on what vehicle I should aquire the tail housing from? Maybe an Expedition 4wd? My parts guy at Ford told me there were 3 different tail housings in 02 for the 4r100 but started whining about needing a tranny tag. I was thinking a 2wd, 4wd and maybe a diesel something? Is the L output shaft stronger?
When I get this project complete I will post it. I have found alot of people inquiring about swapping and few doing it, and when they do, it is usually a 2wd.
The output shaft on the 4x4 tranny is different. It is shorter becasue it has to mate up to the transfer case adapter. The L tranny is a 2wd tranny, so it will not work. A Superduty tranny uses a different T-case, NP vs BW, so you will still need the F-150 adapter. A 4R100 out of an Expi should work.
JMC
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Regards
Jean Marc Chartier
4.6 to 5.4 swap, M5OD 5speed w/Modified Hurst short throw, Warn XD9000i, Troyer E-fans, Procharger @12psi, Troyer tuned. ;)
There are apparently sensor and a non-sensor tailhousings. Since I have an OSS in my transfer case can I use a non-sensor 4x4 tail housing and then just plug new harness into the transfer case sensor. It is a manual shift tailhousing so I assume it is used primarily to pick up the shaft speed for the speedometer. This would either have to be done in Xfer case or at rear axle to correct for low gear range.
It doesn't matter what gear or range you are in. The Output shaft sensor picks up what the output shadt speed is and translates that into the input needed to run the speedometer. Most all of the 4x4 trucks use the sensor on the extension housing of the transfer case because there is no sensor bung on the 4x4 tranny extension housing. It serves as an adapter to the t-case. Regardless if you are using a 4x4 tranny it will have the proper adapter/tail housing. Your tranny wire harness should be able to plug right into it.
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. both are 5.4s. I have to switch the tail housing and also the output shaft so that the tranny will mate up to the transfer case. 
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