So ive been doing lots of forum stalking to hopefully be underprepared for a SAS swap lol. I plan on doing front leafs with whatever axle i choose when due time comes. My question is:

if i source a 98+ 2wd ranger, would the 4wd cross member bolt up to the frame? I already plan on changing the trans tail house to support the transfer case and swap in a manual transfer case to avoid wiring headaches ( ive read i need certain manual trans years for the threaded bosses for a manual transfer case).

the ranger edge trims are already torsion bar setup so does that allow for the crossmember swap to be easy or will it require fabrication?

i am fully aware of the time, money, and fabrication needed for the ranger swap. Would like to get the best starting base of frame to avoid to much “homemade” fabrication aside from the sas.

 

If you're looking to avoid the home-made fabrication on transmission mounting, you're looking for a 2001-2009 Edge 4x2 or Sport trim 4x2 if you're not starting out with a 4WD.

As for the 4WD Transmission, 2001+ manual trucks require the output speed sensor that is mounted to the extension housing of the transmission. If you are going with a manual transmission, 1998-2000 M5OD 4x4 transmission have the thread bosses for the manual linkage, but no output shaft speed sensor hole. 2001-2011 M5OD 4x4 transmission have the output speed sensor holes, but no thread bosses. The ONLY truck to have both the OSS and the thread bosses is the 2002-2003 Fx4 Off Road and Fx4 Level II. Just two years only.

As for the manual transfer case, there's a few issues you'll run into with that. The last year for optional manual transfer cases (for all trims) was 1994. That was the BW1354, and just a few years prior, they were using the less desirable 1350. The 1354 is more desirable, but was only around for 4 or 5 years at the beginning of the 90s. These manual cases tend go for over $1k since most junkyards know what they are. The same can be said for the manual 1354 in a 2002-2003 Fx4 Off Road or Level II. Due to such limited runs, it can difficult to find the manual linkage needed for the t-case along with the t-case. Linkage for the 1350 is similar, but the arm that engages the lever on the transfer case is shaped differently and possibly shorter, so may need modification to work with a 1354.

The same goes for the OSS/Thread Boss extension housings for the M5OD. I have seen people custom make thread bosses to bypass finding the rare extension housing (shown below), so that's not the end of the world.

Keep in mind that the 1998+ transfer cases use tulip style driveshafts that don't hold up well to lifts of any kind. You'll need an adapter that will allow you to run a double cardan style front shaft as that works best for SAS trucks.