Modifications to the '91 Bronco :)

[Alvin in AZ]

A little at a time but working on swapping in a ZF into my '91
E4OD Bronco and came up with this one today...

This is what I found in my '90 F250 parts truck...
http://www.panix.com/~alvinj/file12/pushrods.jpg
...a wore out push rod and stud.
So I knocked the stud out and used the brake's pushrod stuff
off the Bronco's brake lever so I can use a brake push rod for
the clutch.

You know? :/ The like-new brake lever wouldn't fit the cross
shaft from the manual pedal assembly. Ford was still up to
their old tricks, even in '90. So I removed it's "like new"
brake stud and pedal pad. LOL

Still need to weld the stud tomorrow and along with that,
weld the "like new" pedal on the old clutch lever too...
http://www.panix.com/~alvinj/file12/pedal.jpg
...it's peened into place right now, ready to weld.
It'll be like my '75's pedals. LOL

And here's another "new" part for the Bronco...
http://www.panix.com/~alvinj/file12/A9P.jpg
I haven't got the MAF sensor or any of that yet, just the A9P
so far.

Alvin in AZ

 

[Skandocious]

Nice man! I'm jealous. I want a ZF so bad

 

[89frankenford]

Nice man! I'm jealous. I want a ZF so bad

same here BUT ive got a replacement M5OD waiting for a new clutch kit to go in

 

[Mr. Stroker]

We did a ZF swap on a buds truck.. Awesome swap and i liked driving it when it was a manual than the auto.

 

[Alvin in AZ]

Hi guys

Was reading these old threads I started last year about my new '91
Bronco. Sure enough learned a lot of new stuff since then!
Thanks to you guys and others and just time spent tinkering too.

So, this is an 11 month update.

Got a 3 day permit for it this last weekend and actually got to drive it for
the first time ever. LOL Towed it home and put it up on blocks about 11
months ago. Its new name is "Rattle Trap" since it's a desert rig... all the
rubber is hard and shrunk down. That's easy enough to fix, but the name
will stick. Already bought 45 square feet of Dynamat Extreme to put in it.
There's no carpet, headliner, door panels or plastic wall panels in it now
so "Rattle Trap" was a pretty obvious name, huh? LOL

Started it a couple weeks ago. Used a cotter pin puller to operate the
ignition switch-part and it fired right up and idled like a dream! Drove
it all weekend using the same system, hadn't got to the big re-wiring job
I've got planned with the dash-mounted '74-C700 ignition switch and dash
mounted speed control, kill switch, etc.

I -threw- the ZF back together changing only the synchro rings, turns out
it could use some new synchro hubs and sleeves too especially 3rd gear.
No big deal, it'll go a year the way it is, easy. I'll put new bearings in it
next time too. Until I re-discovered the cleaning abilities of used brake fluid
that was by-far the hardest part of taking both the E4od and ZF out and
taking the ZF apart and putting the ZF in. ...was cleaning the outsides of
them two dangged transmissions with all their ribs etc. Never had so much
trouble cleaning anything before. ATF part of the reason, you suppose?
Never cleaned an automatic transmission before.

Not sure how long it'll be up on blocks this time but hoping to swap plates
over to it the next time I drive it.

Seems to have plenty of get-up-an'-go at this point so not sure what I'll
"need" to do to the engine, if anything, but will still go MAF + A9L.

It seems to handle pretty good, better than I figured it would but getting
the TTB 44's weight off the front can't do anything but help that part?
"Road Queen" will be another name for it. LOL

There's a weird thud/clunk coming from the rear axle, don't know if it's the
clutch pack or just looseness in the 8.8? Either way, the plan is to rebuild
it sooner than planned. Carbon discs are planned and keep it 3.55 ratio.

Here's a few pictures, prob'ly nothing I haven't posted in other threads
when they were needed tho...

http://www.panix.com/~alvinj/file12/hoist6m.jpg
http://www.panix.com/~alvinj/file12/hoist7m.jpg

http://www.panix.com/~alvinj/file12/exhaust1c.jpg
http://www.panix.com/~alvinj/file12/Bronco2wd.jpg

http://www.panix.com/~alvinj/file12/BroncoY.jpg
http://www.panix.com/~alvinj/file12/BroncoY1.jpg

And Cornholio ain't got nuthin on me, 'cause I got more than one bung hole...
http://www.panix.com/~alvinj/file12/BroncoYd.jpg

Alvin in AZ

 

[LEB Ben]

Glad you're making progress Alvin. I always love your updates and reading about how you tinker. Keep it up.

 

[Alvin in AZ]

Glad you're making progress Alvin. I always love your
updates and reading about how you tinker. Keep it up.

Thanks for the kind words Ben and the recommendation
to FSB way-back-when too!

Alvin in AZ

 

[LEB Ben]

Not a problem Alvin, I always enjoy reading your perspective because it always seems to be so simple, yet it works. As for FSB, not a problem. I figure everyone who owns a Bronco should be a member over there.