Hi everyone, I've finally made some progress on my Bronco and thought I'd start a thread to maybe help anyone out who is considering the same type of project or get some opinions/info for myself.
Here's the vehicles I will be using parts off of:
1988 Ford Bronco
2004 F250 frame. This was a 5.4 with automatic transmission extended cab short box
1997 F250 diesel with automatic. I bought this truck at a local Manitoba auction with a salvage title. I don’t know a whole lot about the truck except it was running a veggie oil setup that the previous owner took off, came with an auxiliary idle controller, has a positive air shutoff, banks intercooler, banks gauges, downpipe and exhaust, and I've never had it running. It cranked but wouldn’t start. It has ~187,000 km
It took a pretty good hit on the passenger side
Select Parts from my early 1999 F250. My daily driver bought it in 2007, stock
What I've got planned for the Bronco:
• Use the super duty axles from the 99 F250 with 3.73 gears. The front is a dana 50 (the 04 had a dana 60 with 4.10's so those axles front and rear are now in the 99). Wanted disc brakes and wheels and tires to interchange between the bronco and 99
• Leaf sprung front suspension (for now). I'll have to see how this will ride and how well the gas leaf springs from the 04 will hold up to the weight of the diesel. Any thoughts?
• Engine: dp tuner (have in the 99 and like it), DIY intake with AFE big boost (have), terminator modded HPOP (should be back from Joey soon), CCV mod (have), reuse the gauges, exhaust with an 08+ stock super duty tip, and intercooler
• RBP 91R in flat or gloss black, depending on paint choice
• 35x20 general grabber red letter tires or Nitto Trail Grapplers
• 97 front end conversion to look like the newer body style
• For paint I'm considering a matte pearl white like the Lamborghini Bianco Canopus with color matched bumpers, grill, headlight bezels. I also have a fab fours rear bumper that I want to put on but will have to modify the bumper or body
The bronco is currently at the lake so I am only able to work on it during the weekends so progress will be slow
The first thing I did was bolt in the rear 10.5. This bolted in with no problems it even looks like the e-brake brackets are the same and same distance from the axle from the 04 to the 88. The speed sensor also plugged right in. Brake lines aren't hooked up but I'll probably be using the booster, etc from the 97 so this can be done at a later time. The frame on the 04 looks like it is about 0.5" wider but the pins fell into the perches with no problems but I will keep an eye on it. One of those things that upon measuring doesn’t seem like it would work but did.
I'll try make a point of taking more pictures with a camera not just my blackberry
I put in the 04 F250 blocks only so I could tighten the U-bolts properly but I gained a couple inches of lift that I wasn’t looking for (used to barely fit in my garage with 35's). I'll have to play with blocks and angles when I see how far back the transfer case will sit. It looks like the rear leafs from the 04 would bolt in but I wasn’t sure how stiff the ride would be compared with the Pro Comp lift leafs I have in right now. The 04 leafs would probably sit about two inches lower but have four thicker leafs opposed to the five thinner leafs on the Pro Comps. Probably just get shorter U-bolts
I thought I should pull the engine before tackling the front suspension
The frame where the front hangers mount looks to be about 1.5" narrower on the Bronco so I'm thinking I'm going to cut the extra width I need off the 04 frame and weld it onto the bronco frame. I have the factory hangers from the 99 without that brace the 04 has so I will be using those. The brace will help for keeping things square when mocking it up. Might also be important to note I've never done any welding so it will most likely be my cousin coming down as he's a welder. For this reason the more that bolts into place the better.
While I've got the tractor at the lake I might as well prep the diesel to be pulled and do them both at the same time
I won't get around to working on it again for a couples weeks due to an upcoming fishing trip but I’m hoping next to remove the engine, trans, and transfer case from both trucks which I'm sure will raise a lot of questions