I currently have a A4WD, 4WD hi, and 4WD lo transfer case and i want to look into having a different transfer case that incorporates 2WD to those other 3 drive settings. Is this something ford could do easily or wold it be a big expensive project? Would it help with gas mileage?

 

I don't know the answer to that but would freewheel hubs in the front not achieve the same end, more cheaply and simply? (assuming there is still such a thing as free wheel hubs on newer 4wds)

 

You will at the very least need a new T-case with shift motor and switch. The GEM might need to be replaced too. The GEM is what shifts the motor not the switch. As there is an extra position on the switch for 2WD and your GEM might not recognize the extra position. Your front Differential doesn't have the shift collar that disengages the front axle so any economy that you are thinking of obtaining by being in 2WD will not be that much.

JMC
PS. If you still want to do it let me know and I will look up more info. This is all off the top of my head.

 

the main goal would to try and get better economy because i dont need the AWD system all the time and i was hoping that the 2wd transfer case would gain me a couple mpg.

 

Look up the twin stick atlas II transfer case. It gives you 2wd, 4wd hi/lo and 2wd low. You can also shift out of any of the low ranges while moving. You are not going to save money by installing that beast. Its spensive and would take custom installation.

Overall, by modding your stock truck, it will probably be unrealistic to recoup the costs.

 

how custom would an install have to be to run an atlas 2 transfer case?

 

You don't have an AWD system. "A4WD" means Automatic 4WD; that's not the same as All-Wheel Drive. When it's not automatically in 4WD, it's in 2WD, so it's doing what you want (naturally, the engineers designed it to give you the best mileage).Park the truck & drive an Escort or Focus. You'll spend more doing the conversion than you'd save in 10 years from the change in gas mileage.

 

i shouldn't have said that i wanted better gas mileage because that isn't the main reason i was asking about the transfer case swap. I would like the option to have 2wd and the a4wd is not true. The truck is in all wheel drive in this mode not 2wd.

 

What year, and what truck do you have?

JMC

 

2000 ford expedition 5.4L

 

In 97-98 MY Expeditions Ford uses a 4 position T-Case. 2WD, A4WD, 4WD HIGH and 4WD Lo. You could try to fit one of those to your truck. They used a 4 position switch so you will need that too. The big question is weather the GEM will recognize the 2WD position. The switch uses different resistance values to tell the GEM what position the switch is in. You will still be spinning the front driveshaft in 2WD because you don't have the center axle disconnect system.

JMC

 

Which will make any increase in efficiency just about negligible.