Re: 1991 5spd trans problems
I'm not sure about the trans, but going from an electronic to manual transfer case will require some work, console replacement, and some drilling (for the lever). I don't blame you for wanting a manual case. Electronic cases aren't that much involved and can cost $$$ down the road, if you haven't dumped a good amount of money on it already...just wait. You're best bet with the transfer case is to find a doner vehicle, this way you'll save $ on parts, and you'll be able to use the transfer case from the other vehicle. I can't say for certain if the electronic one will work as a manual version due to the fact that it might not be fitted properly to have a shift lever.
I'm not sure if it would help any, but WELCOME TO RICHMOND GEAR
has some good manual units, OD and non OD. As you have a '91 it shouldn't be too hard to find a heavier duty unit, or at least something that's close and will bolt on without much fuss (new bellhousing, etc).
'00 Durango R/T 360ci 290hp (modded); 138,500m
'06 Pontiac G6 GT 3.5L 220hp; 44,000m
'12 Chrysler 200 Limited 3.6L 283hp; 13,000m
'99 Taurus 3.0L 2V Vulcan 145hp; 154,300m - Traded
Amsoil in all vehicles!