If you want to run the 4r70, I would not sweat 2". That length could change depending on what outputs/yokes you ran on the transfer case.
The issue isn't the driveshaft lengths as much as how far back you can shove the engine to maintain proper balance and upper link clearance. The longer the drivetrain is, the further forward the engine is going to have to be which is also going to force the front axle further forward. This is going to affect the balance and CG location, which in turn affects suspension geometry.
What engine? I bet if it comes down to it you can find 2" you don't need in the accessory drive.
5.0L and probably going to run an Explorer serpentine setup which I believe is about the most compact accessory drive setup you can run.
I also got out today and took some measurements and weights on my C4 for the 4600 Bronco. It is a Pan fill C4 with a 164 tooth bell for reference (from an Early Bronco). The transmission and converter didn't have any fluid in them as well.
The bell housing is 6.25" face to face and weighed in right at 10Lbs.
The Case was 11 1/16" long and weighed 83Lbs (W/ the dipstick tube, picture on the scale with the bellhousing & perspective is off)
The factory Bronco C4 to Dana 20 tailhousing was right at 7.5" and weighed 24Lbs (26Lbs W/ the factory 28 to 6 spline adapter coupling, again the perspective is a little off in the picture of the scale). Advance adapters sells a
27 spline output shaft with a 2.90" aluminum tailhousing for the C4 but they also sell a version of the Atlas that bolts up to the Bronco tailhousing.
I also weighed the completely drain factory toque converter, and it came in at 25Lbs.
So here's where I am at with the transmission options:
C4
Pros
- 24 13/16" Long with factory Bronco tailhousing or 20.2" long with Advance Adapters 50-2905 tail housing
- Only 119Lbs (with factory cast iron Bronco tailhousing, probably 100-105Lbs with aluminum short Advance Adapters tail housing)
Cons
- Harder to find; not many show up in the junkyard these days
- Worse factory gearing (2.46 1st) and no overdrive; Dynamic low gear set (2.9 1st, 1.6 2nd) is an additional $900
4R70W
Pros
- Plentiful in the junkyard
- 2.84 1st gear and .70 overdrive
Cons
- Long; 27.5" and no way to decrease length
- 146 Lbs and the converters may be significantly heavier
My current build plans are 42" tires and the '07 Superduty axles I already have, which can only be geared down to 5.38, so I don't need an overdrive. However I think I will eventually want to go rear steer, and if I do I will want to run 9" based fabricated axles (maybe portals too if I win the lottery). In that case I would likely run 6.50 gears (lower with portals) and and overdrive would probably be nice to have at that point.