1996 Ford Bronco "Moose" Build - Ford Bronco Forum
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post #1 of 280 (permalink) Old 12-31-2013, 02:24 PM Thread Starter
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1996 Ford Bronco "Moose" Build

So in late May I picked up a 1996 Bronco that I decided I wanted to fix up for my first car. I liked trucks and when I did some research and found Broncos I knew what I wanted. It would be a perfect off roading truck and a nice daily driver since I don't need to commute too far to school.

It needs some work but nothing too bad for over 150,000 miles. I got it for a decent price and it will be a nice project. She needed some transmission work, body work, maybe some new paint, and some other TLC. Just the normal Bronco stuff. My dad used to have a few Blazers back in the day so he's excited to give me a hand with it.

5.0 L
Automatic
Two sets of tires, 42 inch Super Swampers and a set of 35s.
Paid $2,700

I've been watching some forums on the site and finally I'm getting around to posting its been about 5 months so I have a lot of progress to share, so I'll get started.

Here's a few pictures of the truck when I got it:





The big 42's





I had to put some stock tires on the front to get it to fit onto the car trailer.



So after we loaded it up we brought it home and I had the urge to see it with those 42's since I knew I wouldn't have them for too long. So me and my dad made it our first job to put them on.





The next thing on the to do list was to play around with it and ended up finishing off the transmission in the backyard so we had to limp back to the driveway in reverse.

Last edited by BroncoJoe96; 02-24-2016 at 10:25 PM. Reason: Fix Pictures
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post #2 of 280 (permalink) Old 12-31-2013, 02:33 PM
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pic.s not working?



Stock 302, 3g Alternator upgrade, Catco y-pipe/Cat to high flow muffler, AOD tranny w/remote filter, rebuilt BW 1356, sliding rear side windows
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post #3 of 280 (permalink) Old 12-31-2013, 03:04 PM Thread Starter
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They aren't showing up for some reason...
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post #4 of 280 (permalink) Old 12-31-2013, 03:12 PM
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The pics work on photobucket
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post #5 of 280 (permalink) Old 12-31-2013, 06:23 PM Thread Starter
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Does anyone know how to make them show up here? I took a lot of them and it'd stink for them to not show up here.
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post #6 of 280 (permalink) Old 12-31-2013, 08:34 PM
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Copy the image address form photobucket and then paste.
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post #7 of 280 (permalink) Old 01-01-2014, 01:23 PM Thread Starter
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Next thing to do was to start tearing her down and get the transmission out so we could get her driving again. I had some free time so I took off the fender flares and power washed her so I can see all the rust.



The PO cut the front fenders to try and fix the rubbing that occurred with the 42's. Also there was rot over rear wheel wells and a few assorted rust holes around.

Took off the bumpers and was playing around with a grill guard off one of my dads old trucks, I think when I get around to putting it all back together I'll weld it on.



Here's another view of the rot. Isn't too bad compared to some trucks, but still isn't pretty. Also was the last time I had on the Super Swampers before I sold them.



Opening up the can of worms be removing the tailgate. Also realized the back was sagging down because it was just hanging. It rotted right off.







Also discovered the rear body mounts weren't doing much. We were able to pull them right threw the frame. (Sorry about the fuzzy picture.)



So there she sat.



Up next was the transmission.
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post #8 of 280 (permalink) Old 01-01-2014, 01:54 PM Thread Starter
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Transmission

Before we tackled the body work and rust, we had to get this beast moving again, so it was time to pull the trans. First we got the drive shafts and transfer case out of the way.



Then was the transmission, me and my dad built a cradle to hold it that fit into the jack, and a big U to hold it on the engine stand with 3 bolts to hold it on there.











Pulled off the torque converter and it was time to stat the rebuild.

We went online and got a rebuild kit along with a manual and DVD.

Here's some pictures with it all opened up. And I forgot to mention its an E40D automatic overdrive transmission.






The shifting linkage













After the tear down and rebuild, it looked like everything was fine except the first forward gear drum. This wear ring in it popped out and shredded the spring and welded all the clutch plates together with the heat it generated. Found a whole used drum on eBay for $20. Then it was time to get it back in the truck.


Last edited by BroncoJoe96; 10-16-2016 at 03:44 PM.
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post #9 of 280 (permalink) Old 01-01-2014, 02:24 PM
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very nice holding fixture!!!!!!!

Please provide conclusions to your threads. If you posted a thread looking for help and was provided a solution or got help or whatever, and you were able to fix your problem, please tell us what and how it happened. Part numbers are nice too.
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post #10 of 280 (permalink) Old 01-01-2014, 02:33 PM Thread Starter
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Onto the Body

I forgot to mention that while I had the trans out I got in there and painted the frame and replaced an O2 sensor.

But I finally got it all back in there...

And it worked

I spent most of an afternoon driving it around and it was a blast. But then it was back to work. Time to make her look pretty. Started by pulling the gas tank so we could weld with out much worry of a fiery explosion.



In some places it was rusted pretty thin so I decided to pick up a new one off eBay. I think I got it for $65. Then I replaced a rusted out shackle.



While we were working on the frame we also fixed the body mounts.


A fresh coat of paint never hurt anything.


And then it was time to start on the wheel wells and body. I got replacement panels off LMC trucks.

Area to cut out


Rear rotted cross member cut out








Also picked up a visor for my birthday. So this is now about Septembers pregress.


Patching holes


More body mount holes to fix.


New panel welded in.


To be continued...
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post #11 of 280 (permalink) Old 01-01-2014, 08:01 PM
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Nice work so far. I wish my father was into doing this type of stuff like your dad is. Mine just likes watching!
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post #12 of 280 (permalink) Old 01-01-2014, 08:44 PM Thread Starter
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Thanks guys, and it's great. He's a huge help.
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post #13 of 280 (permalink) Old 01-01-2014, 09:15 PM
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You are working hard. How old are you btw?

94 Ford Bronco 5.0 - working horn and rear window
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post #14 of 280 (permalink) Old 01-01-2014, 09:54 PM Thread Starter
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I'm 16. It's good working with my old man. Picking up quite a bit of knowledge.
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post #15 of 280 (permalink) Old 01-02-2014, 01:09 AM
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Nice build. Where you get the trans rebuild kit and how much?

(Sold) 1999.5 306,000 miles 7.3 SCSB F-250 PHP Hydra With (Swamps Hybrid Inj tunes) 160/100% Inj etc 2008 J2 6.4 F-350 CCSB DWR Spartan 4000 HRS 84,000 miles etc 2012 6.7 F-350 CCSB Spartan etc
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post #16 of 280 (permalink) Old 01-02-2014, 01:25 AM
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Nice job.
I also have to replace my rear cross member as well as rear body mounts. Can you get a few pics of the cross member you build as well as the install.
I am sure I am not the only one that they would help.
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post #17 of 280 (permalink) Old 01-02-2014, 08:08 AM Thread Starter
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There was a bunch I saw on ebay, the one I got ran about $200. And sure will. I have them, I'll just post them in a few hours when I get home.
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post #18 of 280 (permalink) Old 01-02-2014, 08:28 AM
Beach bumming it ........
 
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Hitting it hard man. It's good to see yall bringing this Bronco back to life. Great work.

Nothing better than working with your dad on a truck build.
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post #19 of 280 (permalink) Old 01-02-2014, 09:14 AM
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damn i remember seeing this on craigslsit a while back when i got my last bronco looked clean but boy was i wrong lol good to see her get a new lease on life

(96 Bronco Xlt,93 frame,94 axles,96 body, 6 inch Rough Country lift 36x13.5 swampers) SOLD :(
1991 Bronco XLT ....stock for now
Just because it's rusty dosent mean it ant trusty
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post #20 of 280 (permalink) Old 01-02-2014, 12:45 PM Thread Starter
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I'll have more posted up in a few minutes. This was only the first half of the build. And does this ad look familiar? Haha

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