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Project Merc....

Thank you brown santa...

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X2!
 
Today I will finishing up the Tcase swap. Luckily this year the speedo runs off the rear axle abs sensor. So I am good to go.

As you can see the AWD case on the bottom is tiny compared to F150 BW4406 manual shift case. So I have clearance a few areas for it to fit. The new rear driveshaft uses massive 1350 u joints. So should be able tow with this rig pretty easy. :)

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Don't take that thing for a swim.
 
Don't take that thing for a swim.
LOL The new ones are all sealed.

Long shaft old Merc rear. The middle is Expedition and tiny one is Jeep Cherokee.
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So this shaft is from Automatic 4.0 NP231 Jeep Cherokee. It is perfect length. And then I have this yoke for double cardan from Ford Ranger or Explorer that had a 1354. Fits like glove. And no weird U joint to mess with.
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looks like some jeep fab to me :D
Only difference is my shifter bolts to the transmission and is solid as rock. Isn't made of sheet metal and tooth picks like a Jeep shifter. LOL ;)

Got the filters mounted. Sucks I have to remove battery every time but There really wasn't room anywhere else. Had to make a few adjustment to the battery tray. But worked out good.
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F150 inner boot works good. And looks nice enough for me. The rubber boot part is super thick so should be good to keep the noise down.

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And having 2 wheel drive and 4 low is awesome. I had to hold brake cause the thing was trying to climb my driveway in 4 low. LOL Love it!!!

Now I just need tires to get here and some headlights. Sliders and front bumper this week. Getting closer!
 
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