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bats 88 Bronco II Build Up

Discussion in 'Bronco II Registry' started by bats, November 2, 2011.

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    1. bats

      bats Active Member

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      I love the smell of 30 year old gear oil in the morning! Completely tore down the axle save for the seals in the pumpkin. Barely any gear oil in it and there was definitely moisture in there. Rust on everything but it's serviceable. The shitty Rustolem paint job some one did on the axle is bubbling and pealing. I'm thinking it need a good sand blasting.

      I ordered the more expensive parts (4.56 Ring and pinion and a rebuilt kit) along with some miscellaneous duff stuff. Looks like my family won't be getting Christmas presents this year...
       
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    3. vroomzoomboom

      vroomzoomboom Elite Canuck STOCK SUCKS! Elite Explorer

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      the truck is considered family, isnt it?
       
    4. janderson4010

      janderson4010 Moderator Emeritus

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      Dude I haven't checked out your thread in a while, but hell yeah on the Sas.
       
    5. bats

      bats Active Member

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      The SAS is probably going to be next winters project. I've got too many funds tied up working on my parents house and traveling. Me and my buddy drunkenly decided to do a trip to Europe and I have some R&R in a much warmer climate coming up in a few weeks.

      The Silver Bullit Bronco is still rocking though. I took it out to the inlet with my Jeep buddy and once again swamped it and hit a few local 'trails' pretty hard. No major breaks other than a bent muffler and some water damage. It's getting its fair share of abuse.

      Time is coming for some maintenance though. Oil change and hub regrease etc. The saltwater from the beach is worse than the road salt which seems absent this year.
       
    6. janderson4010

      janderson4010 Moderator Emeritus

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      Stuff gets put on hold man, my cage hasn't been worked on in over a year haha
       
    7. bats

      bats Active Member

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      Sometimes life gets put on hold in order to allow us to pursue other sorts of ventures and interests.

      For now, here's some pics til the next big update:

      Drowning it again. By the time I got out the driver side lip dipped below the water.
      [​IMG]

      Just a nice day for a cruise.
      [​IMG]

      Closing with a poser shot of the little beast:
      [​IMG]
       
    8. janderson4010

      janderson4010 Moderator Emeritus

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      it blows my mind how well these things do with 31's and maybe a rear locker. that 4.0 does add considerable pep to them though.
       
    9. bats

      bats Active Member

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      Whadya want for free?

      Drifting a lifted truck in the snow is immature, dangerous....and fun as hell! I've been having a blast in the snow. The little beast claws its way through every snow drift I've plowed through/over.

      My biggest problem is still ground clearance. The only thing that stopped me were some ice chunks that I got high centered on. Hopefully the SAS helps with that. They don't call the TTB a snow plow for nothing...

      I did get in a little fender bender with a boulder I was trying to climb. It was so icy I slid down and landed straight on the bumper/fender.
      [​IMG]

      Somewhere after the start or the new year, I inherited a 98' Expedition from a relative who gave it to me for nothing.

      [​IMG]

      The plan is to make this the tow pig so I can properly use the Bronco when I go offroading. Of course, with any free vehicle comes a bunch of problems.

      The truck has the 5.4 litre Triton V8 which I'm told is a very tough motor. How tough is it? Apparently good enough to run on 2 out of 6.5 quarts of oil for god knows how long. It also came with some shitty electrical work and I had to wire a push button starter due to something in the steering column being jacked up. I was pretty pissed after laying in a snow bank for 4 hours yesterday changing the starter only to have it not fix the problem.

      I hope to at least get a year out of the truck. At 180,xxx it's been through some shit. Actually, as long as it gets me to Carlisle and back this year, I'll be happy.

      Since I have this truck as my new DD (All Expeditions come with this neat feature where you can literally watch the gas gauge go down) the Bronco is once again being parked for some patch work.
       
    10. janderson4010

      janderson4010 Moderator Emeritus

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      I have a 04 Expy and I love it. It doesn't do to bad on gas , like 16.
       
    11. bats

      bats Active Member

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      So there's good news and bad news...

      The good news is I brought the D44 inside to warm up. Armed with a bottle of Jager, a lot of coffee and 200$ of the finest Chinese made tools Harbor Freight has to offer, I did it. Gear pattern came out pretty good. I guess I don't officially get my 'setup your own gears' merit badge until the 100 mile break in.

      [​IMG]

      Was not as bad as I thought but next time I'm having some one else do it.

      Neat little trick I learned for when you forget which bearing cap goes which way. I threw all the nuts and bolts in a box when I tore it down a few months ago. If you look on the caps and look on the housing you should see a corresponding letter. The letters vary from axle to axle but the concept is the same.

      [​IMG]

      I've been kicking around the idea of a body lift for a while. Even went as far as buying a 2" one. Well, I decided to go for it. I have clearance issues at full stuff and I don't want to cut my fenders any more. Pacer flares will eventually cover up the cut and roll I did on the front. The rear tires scrub the tub.

      All the bolts came out just fine. And the drivers side is now jacked up and waiting for the replacement body bushings I ordered. So far so good, just take your time.

      The bad news is that the rust problem is worse than I thought. All the body mount holes were filled with a sand/rust mixture. On the passenger side I peeled up the Peel n Seal and discovered that water and antifreeze had been pooling in the kick panel area. Looks like I'm doing a heater core and another round of silicone.

      [​IMG]

      For the most part, the body mounts were in OK shape:

      [​IMG]

      Borrowing a welder and will take care of that later in the week. All the mounts are getting a wirewheel and Rustoleum treatment. The body came off so easily that I'm considering removing it completely and giving the frame a good once over.
       
    12. bats

      bats Active Member

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      Ended up not doing a frame off job. The other mounts were actually completely solid. It was just the middle mounts on either side that were bad. Replaced all the other bushings and the lift and it's now 2 inches higher. Not terribly noticeable unless you look hard. I think 2" is just right since it gives me more room for.....stuff.

      The kit said to reuse your original hardware. Ha! Maybe half of the hardware came off on its' own. The majority had to be sawzalled off. Make sure you plan for this and pick up an extra set of lock nuts and washers.
       
    13. bats

      bats Active Member

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      Just came in for a beer break and figured I'd update. Took the body lift off. Took all of 2 hours from start to tightening the last nut.

      I tried the body lift thinking it would help with my fender clearance problems...and future proofing for a possible V8 swap. Well, it didn't solve any problems and I decided against a V8. Just have too many projects going on right now to get involved in another engine swap. The SAS is on hold probably till the winter. I'm still committed to that though.

      Have a few wheeling trips coming up in June which I need to get ready for.
       
    14. bats

      bats Active Member

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      Well June is nearly done and wheeling didn't happen. Didn't make it to Carlisle and the trip that was planned for this weekend didn't happen either. The truck has been parked since last update. Seems like every one's sh!t is broken or broke. I'm noticing a lot of local kids are selling off their rigs. (Mostly Jeeps.) Can't make rent if you're pouring money into a truck that only goes to 7-11 and back. Seems like the offroading community is in a slump out here.

      Hopefully that will change by the end of the summer. After these last few upgrades I think I'm going on hiatus from working on the Bronco. I still have that P.O.S. YJ I have to put together so I can get it out of my yard as well as a rat rod I've been working on since high school.

      Few weeks ago my friend picked up an Eddie Bau BII that had an engine fire. Fuel injector leaked and *poof.* I picked up a complete interior seats and all for cheap along with some miscellaneous bits. It's like having a truck again and not a tin can on wheels! Down side is I tossed all the hardware for the rear seats.

      My steering has been sloppy for a while but I finally took care of it when the steering box blew a seal and pissed all its fluids out. Did a soft rebuild which is just the gaskets. I'll link to the parts and stuff at the end of this post.

      Figured I would do the Flaming River steering shaft upgrade while I had everything out. The prices have dropped on the FR parts so the difference between them and the borg brand is somewhat negligible.

      [​IMG]

      Definitely an improvement. Power steering pump still whines like any Ford does. Maybe I'll upgrade that to the AGR one but I doubt it.

      Links

      Steering Box Rebuild
      Steering Box Rebuild guide via TheRangerStation I just called Prosteering.com and asked to order part number 8229.

      Steering Shaft Upgrade
      Steering Shaft Upgrade - Flaming River

       
    15. getoffroad

      getoffroad New Member

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      Hello. If you decide to drop in a 302 or have other build questions feel free to drop me a line. I dropped in a 302 in my 84 Bronco II last fall and changed my c5 to a c4. this spring I changed out the c4 for an AOD and other changes. Anyway, I did the same as you, I read all the books out there on v8 swaps and read tech articles etc... Trust me talk to someone who has done it first it will save you time and money. I wish I could have done just that. I will be glad to give you my nickels worth of free advice. I want to hear more about your YJ too. I was building one of them before my bronco II.

      Dennis
       
    16. bats

      bats Active Member

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      Thanks for the offer! As much as the 4.0 really woke up the lil Bastard I still partly regret not going V8. Should have just fixed everything on the Explorer so I would have a mild off roader that I could still drive on the highway. Shoulda, woulda, coulda.

      So the YJ. Bane of my existence since the spring. My buddy picked up a perfectly running, driving and straight 4.0 YJ with the intention of swapping the body from his 2.5 YJ. The frame was half gone in the rear. As payment for using my yard space for a few weeks he let me have the old YJ. Came with a 'new' frame. His body swap went smooth and three weekends and a lot of beer later he drove off into the sunset and left me with a pile of parts.

      Since the spring I've been putting it back together, piece by piece. Repaired the 'new' frame. Tons of nickel and dime parts. Nearly everything was rusted. I've never swore so much at a project.

      Just got it running and driving a few weeks ago. Everything works except the brakes. Replaced the master. All new lines. Bleeds clean but I can't get the pedal to stay. Takes the pumps to brake and ten immediately loses pedal. Arg.
       
      Last edited: September 17, 2014
    17. getoffroad

      getoffroad New Member

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      I had a similar situation. The guy I bought my Bronco II from had replaced the brakes pads and bearings along with all of the front tie rod ends etc. I always had to pump the brakes to stop. Replaced the vacuum booster and the master cylinder twice. I bled the brakes a thousand times. Even changed from old style mc to the plastic body version. I even switched to a disc brake 8.8. No luck. Sometimes I had great brakes then the next time nothing....read all about brake problems and never found the answer. Most forums talked about it but always ended and never said what the fix was. Well mine was that the guy used the wrong bearings. The bearings he used on the inside were too big and didn't even touch the spindle.The bearings he used were for an Explorer or newer Ranger. Once I replaced them I had the best brakes. I dismissed the bearings since they were all new. Anyway it's the little stuff that gets you every time.

      Good luck on the YJ. I think about getting another one but then remember how much I like my Bronco II.....and that I need to drive it for ten years to get my money out of it....lol.
       
    18. bats

      bats Active Member

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      Never just rains, does it?

      YJ needs complete brake job all around. How my buddy was driving this thing is beyond me.

      Enough about the Heep. This is a Ford forum. Over the weekend I took the Bastard for a quick woods romping. Tightened up the steering box which killed some of the bump steer I got while bajaing through some woop-de-dooes. Get back to the house and remember I haven't checked the fluids in a while.

      Oil was a little low and a little milky. Check the radiator and can't even feel antifreeze with my finger. This is after an hour or so of romping and driving. Expansion tank is bone dry. Also notice it's starting to develop a slight miss when idling.

      Milky oil? Disappearing coolant? Yep, bad head gasket. Not sure how long it's been like this but checking it today after driving that coolant is going somewhere and it's not on my driveway.

      I'm heartbroken. Once I cooled down I started weighing my options. Rebuilding the top end is not something I want to get involved with. No way. Now you're probably staring at your computer screen yelling 'V8 SWAP, DAMNIT!' and I'd be yelling along with you but I'm not.

      Why no V8? Like I mentioned earlier, life is changing for me. I'm not offroading as much as I would like or did when I got into Explorers. These little under the radar romps aren't enough to warrant another full drive train swap. In the time it would take me to source the parts it would be easier to just wait for a wrecked Ex to come by. The Bronco still runs and drives but it's a time bomb. :mad: :(
       
    19. bats

      bats Active Member

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      One of these days I should upgrade to Elite status again so I can post pics.

      Sold the YJ about a month ago. It was a fun little toy but the joy goes out of it when all of your toys are crying for your attention.

      Which brings me to the Bastard. Started on the head gasket job. Not so bad. Marking wires and tagging and bagging things. Tried using the Chilton's manual and it ain't worth piss. Compiled a pretty solid work flow based on threads I read here on the forums.

      Got down to the block without breaking any bolts. Those Torx bolts on the heads scared me but they came out with minor cursing and persuasion. Most likely will buy new heads already setup instead of reusing mine. Do it once, do it right.

      As far as I can tell there was no damage to the heads or block which is a relief.

      I fogged out the engine with fuel oil since this is probably going to sit until after Thanksgiving. After that it should be full speed ahead on this. Afterall, Carlisle is 7 months away and I really hope to show my face this year.
       
    20. vroomzoomboom

      vroomzoomboom Elite Canuck STOCK SUCKS! Elite Explorer

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      dont remind me. im looking at another drivetrain swap again and if i can make it there, i might just go for it.......even if i have said for the last 3 years i wont be making it back next year....
       
    21. bats

      bats Active Member

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      I'm not dead yet.

      Not much of an update, just letting those of you still following that the Bastard is still alive...ish. I've been traveling for the better part of November so nothing got done. Checked on my baby today and it's still waiting to run again.

      I lied about the bolts not giving me a problem. Thought I loosened all the bolts but never took the drivers side head off in my haste. Two bolts were stripped not loose and now I'm on the hunt for one of those easy out sets.

      Starting to order parts and gaskets. Not having many folks to shop for around the holidays means more money for projects. So there's that.
       
    22. bats

      bats Active Member

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      Despite it being the holidays I managed to hide out in the garage for a while and get some work done. Got the last head bolt out without issue. Helps when you use the right size torx. It's a T55. I had been using a T50 which worked on most of the bolts but would explain why I stripped the last two.

      Got the drivers side head off and found the culprit. Middle cylinder had been leaking. Doesn't look too bad but definitely was the problem.

      I wanted to order new heads. In fact I did from that link that jd always posts. Placed my order, put my card away and received a phone call that the didn't actually have the heads and were completely out. Major bummer. Did some shopping around and couldn't find any NEW heads at that price point. Gave up and decided to just reuse my heads.

      I know it's taking a risk but visual inspection didn't show any damage. Spent two hours per side up close and personal when cleaning the mating surfaces. We shall see.

      Got the heads installed and the lower intake manifold and then the temps started dropping so I called it quits.

      Advice for anyone else doing this:

      1.CLEAN YOUR ENGINE BEFORE YOU DO ANYTHING! Gunk it, brush it, blow all the dirt and crap out. You run less of a risk or contaminants getting in the block AND you'll have a shiny new-ish engine when you're done.

      2.Make sure you get the right Torx bit. T55.

      3.Read. Read. Read. Print out torque specs/guides/notes and organize your pages before hand so you don't have to run inside to check online for something and get grease everywhere.

      4.Take lots of pictures and bag and label your bolts.

      Overall I don't think this is a terrible job.
       
    23. bats

      bats Active Member

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      Victory at sea!

      Well almost a victory. I put together the last few bits needed and hooked up the battery. To my surprise it started on the first crank! Sounded pretty good... until I noticed the smoke. Had what I thought was coolant leaking down the back of the engine. Got pissed and went inside to defrost for a few minutes.

      Went back out to the garage and immediately realized that it was a gas leak and not a coolant leak. Good thing I turned my propane heater off when I went inside. Five minutes of troubleshooting with my dad pointed me at the problem: one of the injectors was pissing gas. It probably just didn't seat right when putting the fuel rail back on.

      A minor inconvenience at most and I caught it before anything caught on fire. I'll pick up some o-rings and just replace them all.

      In the few minutes that I had the engine running it sounded just as good as before. Can't wait to get rolling so I can start working on my 2015 ToDo list. Lots of fine tuning to be done and even have some trail time already penciled in.
       
    24. bats

      bats Active Member

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      :mad: Never just rains, does it? Might change the title of this thread to that.

      Ordered new injectors from motorman on ebay. Came right on time despite the east coast getting hit with a snow storm last week. Had the hoses recrimped at a local hose store. Fixed one leak and created another. Reused the original fittings instead of spending $$ to redo it with the proper AN fittings. SOL on the hoses since no one seems to be parting out a first gen.

      Might take this oppurtunity to redo the fuel system like I had originally planned. Some nice AN fittings and steel braided lines instead of half @$$ing it with fuel line parts from three different trucks. In my defense, non of them leaked.
       
    25. vroomzoomboom

      vroomzoomboom Elite Canuck STOCK SUCKS! Elite Explorer

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      dan, are you looking for just the fuel rail, or lines? a buddy of mine has a first gen sitting in his yard that i dont know what he's doing with it. i can ask him if he wants to sell, or give up some stuff from it.
       
    26. bats

      bats Active Member

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      Tim, just the lines going to the fuel rail.
       

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