1994 Ford Bronco - The Build Begins

[Bronco85]

So I decided to finally bite the bullet and buy a new rig..

1994 Bronco XLT - 351W and E40D with 140,000 Miles

Plans:

D60 with 5.13 Gears
10.25 with 5.13 Gears and Detroit
10" of lift
Custom Rear bumper
Custom Winch bumper
And fixing everything thats wrong with it.

http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Purchased/100_6802.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Purchased/100_6803.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Purchased/100_6801.jpg

Might Repaint it, don't know yet. It's fading but no rust at all.. Except for a few little scratches and a dent in the roof

More Pictures
http://s773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Purchased/

[AKBearMoose]

now THAT will be fun:cornut::thumbsup:

[TonyM]

Thats a nice bko man...

If you plan on keeping coils up front and are going to go with big tires... Get the CAGE kit. Its a little spendy, but well worth it :cornut:

[Bronco85]

What is included in the cage kit?

I know the Cage arms are what I'm going to buy. What else is there going to be.?

It looks like there's a 80% chance the 85 will be going to my brother in-law. My motor and tranny will be going in an Early Bronco of one of his buddies. We'll have to see.

This is going to be a slow project. It's going to take me all winter to get the bronco as it is now how I want it. Then I'll start swapping things over.

[Kodiak181]

nice looking bronco, and good luck with the build!

[Bronco85]

Finally got the bolts out of the stupid ass floor. Got all the old sound proofing off the floor, going to hit it all with the wire wheel tommarow and clean it up. So I can put the hurciliner on Friday since I have the day off. Hoping the gallon will give me 3 coats. It's going under vynal flooring in the front and the box in the rear. Just extra protection and have the metal sealed...

Then I will start on the dash, and go get my bumpers off the old bronco I think...

[BLB]

Eww.... E4OD

[Bronco85]

Eww.... E4OD

Ya tell me about it. I do have the c6. Just have to find a computer.. Don't think broncos came with a C6.. So soo well.

[BLB]

Ya tell me about it. I do have the c6. Just have to find a computer.. Don't think broncos came with a C6.. So soo well.

Nope Broncos ended the C-6 in 1991. My 1989 had a C-6. Sucks Ford went to the crap tranny

[Bronco85]

You can build up the E40d Pretty stong if you want to spend that kinda money.. I don't really want to at this point.. I'll drive it till it dies and go from there. IT seems really tight right now though. Might have a shift kit installed when I pull it for the rear main though.

[sailin]

the e4od can withstand alot of abuse just put a shift kit in it or valve body and go i know of quite a few that have been through hell and back most being plowtrucks and first gen powerstrokes. However ive had issues with all my c6s just know when to back out of the throttle.

[Bronco85]

my C6 has been through hell.. I regularly over heat that poor thing.. Lots of thick nasty mud that I had it floor in 4 low and the tirse wouldn't spin... :) It still shifts like it's brand new. Granted it probably has only 10,000 miles on the rebuild...

But just for sake of argument. When I had it rebuilt, one of the upgrades was gears from an E40D as well as a couple other things I can't remember.

I was told there is a way to wiring up the OD so that it stays off when you turn the motor on and off. That would be a nice feature, so that I don't have to remember to do it. not that going 10-15 MPH would warrent OD anyways :)...

[TonyM]

I have had NO issues with my C6, and I have run it completely out of fluid numerous times. I am sold on that tranny. If i'm running a ford off road, unless its a zf5 or np435, it will be a C6.

[Mike Honcho]

The C6 is a great trans, one of fords best. But i will have to say ive seen E4OD's come in when i worked for AAMCO thats had 200K plus before crapping out, one was even at 302K and it was a heavy service truck. All transmission have their problems.

[Bronco85]

So it begins with this bronco as well. I went to start it up to move into the garage to start putting the interior back in.. Battery dead. No big deal. I'll hit the charger. Still no go. I put a enw battery in that I know is charged... Still no go. click click, super slow crank... Click click. I go smack the starter a few time with a wrench... Click click, Slow crank this time. Juist hold the starter on for a bit. And it finally works up the speed to fire. It did fire right away though, no sputter or anything.

So sticky starter? Once it gets warmed up I'm goign to try it again.. Maybe there's water or somthing gumming it up.. There's like 10 coming off that damned starter.. Will be fun to trace

Pics of the interior soon.. Putting iot together now..

[ryantowry_81]

did you check all your connections too? corroded connections can do the same thing.

[wayne]

phil with it getting cold and damp it will show a weak starter in a hurry or it could be weal selinoid pack as well ..

mine had the cap of the starter cracked and let moisture in and was a no go everytime it was wet or cold ..

[Bronco85]

Ordered the James Duff arms, new lower coil buckets and some spacers for the Coiled D60. Should be shipping out soon was waiting on bushings. but that was 3 weeks ago. I'll probably call next week if I see nothing.

I will probably start on pulling parts off the 94 this weekend. My brother leaves back home on Saturday so then the fun begins.

I gotta figure out how to get the 85 into my parents garage. gotta go up a hill into the garage. Anyone got a truck that we can use to push it with :)

[Bronco85]

Gotta move the axle forward. I didn't think I would have to chop a ton, but I finally cut the lip on my crossmember and doh!
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/aebced29.jpg

Hi steer arms where a dude. I measured wrong somewhere. But the arms put the draglink way to high.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/0d2b2f0f.jpg

[TonyM]

blocks in the rear, coil bucket drop in the front.... raise it up another 4".... solve all of that madness.... (Except the fender... looks like you'll definatly need to move it forward a bit... maybe have to trim just a little... the world isn't over YET for you and this build....lol :46:

[Bronco85]

Going to pull it all off and move it forward. I should have not been a lazy SOB when I realized what I did orginally. I should have moved it all forward then, and not drilling a million holes in the frame. Now I get to move everything forward and drill a million more holes.

Atleast I got the drilling down. I used 6 different size bits last time, and it went way faster then doing a pilot hole and then going straight to 1/2". This time it should go quick. Going to try and talk my old man into coming over Sunday and havn't fun drilling while the women are doing what ever it is they do when they dissapear day after xmas.

[Bronco85]

Well spent the weekend pulling the axle and moving it forward. Originally I was only going to move it forward 1", but after looking at it I notived I could move it forward about 1.5". So that's what I did. I also relocated the radius arm brackets about 2" forward. Might have been a just a little less. I used an existing hole that was pretty close to 2" forward.

New Tire locations.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/fddba3e8.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/06955af3.jpg

Also was able to center the axle just a little bit better. I don't have the track bar in. I need to fab one of those up.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/02bd5987.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/f4a5fe53.jpg

New Radius arm bracket location.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/7c952451.jpg

Here is where the Track bar needs to go.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/503a321c.jpg

Here's the bronco at ride height. Looks pretty good, the winch and bumper should lower it about 2".
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/28a43105.jpg

[Irish_Inc]

Good progress! I like the forward axle:thumbsup:

[Bronco85]

I'm so tired of drilling holes :) Looks like i can move the crossmember back to the original location also. Just have to cut some of the side bracket. Might look into that later on.

[Chevy Man]

Looking good man... Good progress.

[Bronco85]

Got the Track bar finally welded on. Drag link at 6 degrees and the track bar is at 6-7 degrees (Depends on how I look at the needle).

Front side
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/5af7f851.jpg

Back side
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/1%20ton%20Installation/4ebf32b2.jpg

[RentalMan]

Phil? uhhh... Phil? where'd ya go? Thinkin we need an update there buddy. :sifone:

[Bronco85]

I guess I could update this thread huh :)

Bronco drives pretty good. currently I ripped out the front seat to install a Manaul Tcase and shifter. As well as a custom panel for the CB/Power outlet.

Soon I'm hoping to finally get the winch bumper mounted up and I can start working on the spare tire/gas can carrier..........

[RentalMan]

Awesome, did you end up installing the subs?

[Bronco85]

No, I havn't gotten around to it. I will probably end up just making a box in the side panels for them.

[Bronco85]

Man i havn't updated in along time.. Nothing has changed though really been broke and busy..

Here are a few updates...

Gauge pod Tranny, Engine temp and oil pressure.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Interior%20Work/7e414752.jpg

Switch drilled into the dash, I will probably redo this with a plate now that the 4x4 switches are gone.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Interior%20Work/daf545a3.jpg

CB and power point mounted in old ash tray location
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Interior%20Work/a9f5906e.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Interior%20Work/80842bed.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Interior%20Work/024ef844.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Interior%20Work/9ada71ab.jpg
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Interior%20Work/d65b38fe.jpg

[Polack]

CB? so wheres the vhf going...?

[RentalMan]

dang! That mount looks awesome! Nice work!

[Bronco85]

Thanks, Could of small issues with it. But not really noticable.

I traded the Hard mount VHF Radio for 2 hand held VHF radios so that I could use them out 4 wheelin and snow machining as well.

[Bronco85]

Got a little more done this weekend. Jerry welded up my brackets for me so I could finally bolt on my winch bumper. Need to make some new side braces since I can't use the old ones, and some new braces to hold the top panels in place, and somthing to hide the uglyness of the brackets...





Had to cut the grill and that metal peice under it to push the bumper in farther. I didn't want it sticking out a mile.

http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Bumper%20Installation/da443832.jpg



Head on shot

http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Bumper%20Installation/75b30662.jpg



Side shot

http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Bumper%20Installation/0115fcd8.jpg



I need to make a small plate to cover these gaps, but not sure how much the tire will need for clearance just yet.

http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Bumper%20Installation/80f2ff46.jpg



Uglyness that is the brackets

http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Bumper%20Installation/940126dc.jpg

[Chevy Man]

Looking good man, any new progress??

[Bronco85]

Update. Rebuilt my winch, since my motor died. It's the Oil bath M12000, but according the the warn rep. it was only made for about 3 months because of oil leaking issues. I rebuilt it to grease specs. per the rep. so I should be good to go here's a few pictures.

Winch before I started the rebuild. Well used after about 8 years of hard use and no maintence.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Winch%20Rebuild/837a7483.jpg

Part of the motor. All nice and rusted up. I guess the motors don't seal to well:mad2:
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Winch%20Rebuild/f558d055.jpg

Planetary gear set. These still look brand new.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Winch%20Rebuild/1a1e7d9b.jpg

The entire winch all nice and pulled apart. Not to many parts to one of these things.
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Winch%20Rebuild/85d6d0d9.jpg

All done and pretty:17:
http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Winch%20Rebuild/f4cf2ff4.jpg

[Chevy Man]

Nice, new and shiny! And new stickers huh?

[Bronco85]

Yep.... :)

[Kodiak Dodge]

That bumper looks really good tucked in. You need to get some tube on that thing.

[Bronco85]

There really isn't anywhere to put tube on it anymore. The lights take up what little space there is on the top now. Unless I was to relocate the lights to the tube. I need to fill in the gap to the fender whell as well. But going to wait till I have a chance to flex and see where I can add metal. I'm going to do something with the bottom too to cover the brackets, but havn't decided what yet.

[Kodiak Dodge]

I see plenty of room with your light staying where they are at. I would add a hoop infront of the grill and some tube around the headlights and to protect the corners. Something like this...
http://offroaddesign.com/action/ORD%20Bumper%20Mud%202.JPG

[Bronco85]

I'd kinda like to go somthing like this, with the tubed fenders, and simplier style hoop. I need to get with someone thats good with working with metal to really get it all to look good though.

It's a friend of mines bronco down in LA..

http://i773.photobucket.com/albums/yy12/Bronco8593/94%20Bronco%20Build%20Pictures/Misc%20Stuff/3011396d.jpg

[Kodiak Dodge]

For Alaska wheeling I think the other design will offer more protection to the from when going through brush and trees. I loved having my entire front protected. Really helped keep the body in good shape. plus something like that is a good base to eventually tie into for an exo or semi exo.

[Bronco85]

Very true. My 85 Bronco never had an issue with brush, since the lights where inside the sheet metal. The 94 has more edges and stuff to grab. I'm guessing with the wrap around it will be a bigger issue. I'd have to come up with something that looked better. That design just looks like ass. Maybe a smaller tube... 2" tube for the main hoop then 1" tube for the fender protection? I'd like to do somthing on the back as well. I seen to back into stuff..:)

[wayne]

looks really clean phil , did you swap in the older 351 you had built or used the stock one ?

[Bronco85]

The stock 351W has lots of power.. So There was no need to run the built up motor. Plus I had planned to go IM legal. The heads on the 69 motor don't have the holes for the air tube in the back.

[wayne]

what compression you running on the 69 351w ?

[Bronco85]

Like 9:1.. It runs just find on regular gas.