Hagan's '89 Cummins powered Bronco - Ford Bronco Forum
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post #1 of 70 (permalink) Old 02-26-2017, 12:48 AM Thread Starter
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Hagan's '89 Cummins Bronco 05+ Superduty axles build

Picked up this '89 Bronco on Craigslist for $400 on Feb 19th. It doesn't run and the interior has partially been stripped. Carpet has been removed but that's ok. It looks like it has a 351w and a c6.

I plan on installing my a '92 Cummins engine and I'll be using my zf5 transmission that I already have for this project. It will also be getting a d60 front and Sterling 10.25 rear.

I've been trying to decide on a perfect daily driver and adventure rig and I keep coming back to a Bronco. I have plans for an adventure trip next year.

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1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #2 of 70 (permalink) Old 02-26-2017, 10:03 AM
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Subscribed. Can't wait to see progress and the finished result.

'93 XLT; 5.0 V8; E4OD With Sonnax SureShift (hopefully to be 5.8 and ZF5); 2.5" RC lift; 33x12.5 BFG AT KO2s; 4.56s; Truetrac; Warn Premiums; Flowmaster Super 40 muffler; Sag swap; Redhead steering box

If it moves and it shouldn't, use duct tape. If it should move and it won't, use WD-40.
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post #3 of 70 (permalink) Old 02-26-2017, 02:33 PM
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Sounds awesome, out of curiosity is there any reason you're sacrificing your DD's engine?

Tough to kill an old six
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post #4 of 70 (permalink) Old 03-04-2017, 07:13 PM Thread Starter
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Sounds awesome, out of curiosity is there any reason you're sacrificing your DD's engine?
Mainly because it's a piece of junk.

Been working on it a little bit. I replaced the door lock actuators in both doors and now they both work. Need to figure out the ignition switch. I can't get the new cylinder in the column. Maybe I will just swap my manual column in now.

Decided to go a different route with the axles and suspension. I bought a 2006 F250 frame with axles and suspension. I decided if I'm going to drive it every day I want it to ride nice. I knew leafs would never provide that. These axles provide bigger brakes, stronger knuckles, stronger stub shafts, sharper turning radius, and they are much cheaper to buy.

I'm thinking I will swap to a different Sterling axle but out of Superduty.

I paid $1300 for it but drove 900 miles last night. Left at 1pm yesterday and didn't get home until 8am this morning. Fell asleep at a rest stop for about 30 minutes.

Here is my door lock actuator. I broke the mount in the door and didn't have a rivet that big. A 1/4" bolt half inch long fit perfectly. Doesn't look the best but definitely functional. Ended up scratching the door a little when the drill bit slid off the slid off.





Here are the axles and frame

1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #5 of 70 (permalink) Old 03-12-2017, 12:13 AM Thread Starter
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Got a little bit of work done today. I removed the front clip in order to make it easier to install the engine and for the solid axle swap. Also my dash and interior wiring is hacked up. Dash is cracked and ignition wiring has been cut/spliced/hacked so I pulled a complete dash and wiring from a junkyard for $40.

New dash



1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #6 of 70 (permalink) Old 03-13-2017, 12:18 PM Thread Starter
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Well I made a mistake. I got a wiring harness and dash out of a '90 F250 and at the time my only concern was finding a decent dash. Then once I got it home I realized the f250 won't have the rear window switch or rear defrost in the harness. Looks like I'll either be modifying my harness because I'm missing the ignition plug (it's on the column) or look for a new harness.

1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #7 of 70 (permalink) Old 03-23-2017, 01:48 AM Thread Starter
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Got the new dash in and wired my stereo plug. My stereo is not in yet but will be when I tear the Dodge apart. Only one plug was different on the dash wiring harness on the new one. I ended up just cutting the 2 wires and leaving them hanging there. I can't for the life of me figure out what they do.


1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #8 of 70 (permalink) Old 03-23-2017, 02:26 AM
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Yours is more torn down than mine was a couple days ago. No wonder you were feeling my pain about having to wait for spark plug wires to arrive!
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'92 Bronco Build Thread - '95 MAF 5.0, H5 axle code, York OBA, 3G alt, custom jump seat console, flomaster steps/sliders.
http://www.supermotors.net/28006
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post #9 of 70 (permalink) Old 04-11-2017, 10:44 AM Thread Starter
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Yours is more torn down than mine was a couple days ago. No wonder you were feeling my pain about having to wait for spark plug wires to arrive!
Yeah it's pretty torn down. Seems like all of my vehicles have been torn down like this.

Only progress so far is I've removed the radius arm brackets off the super duty frame. Took probably 3 hours for both and 14 rivets.


1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #10 of 70 (permalink) Old 04-11-2017, 10:55 AM
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I'm stoked to see how this turns out....

1996 Bronco XLT, Work in progress
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post #11 of 70 (permalink) Old 04-11-2017, 11:10 AM
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post #12 of 70 (permalink) Old 04-12-2017, 01:38 PM
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Pro tip I learned removing the brackets on my 90s suspension, get an air chisel/hammer...I must have spent a whole day trying to grind and cut the rivets, neighbor saw and gave me his air hammer...twenty minutes later they were all done.
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post #13 of 70 (permalink) Old 04-12-2017, 02:18 PM
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I gotta see this. Love diesel swaps!
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post #14 of 70 (permalink) Old 04-13-2017, 07:59 PM Thread Starter
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Unfortunately, I might have to scrap the Bronco and frame/axles this weekend. I got a notice of violation for having a "junk" vehicle and parts on my property and not in an enclosed building. It's not like it's been there for years. I've lived here (small town) my whole life and have never had an issue. I've always had vehicles that I've worked on outside. I'm pretty upset and I only have until the 17th. No idea what to do at this point

1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #15 of 70 (permalink) Old 04-13-2017, 08:51 PM
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Man, that blows. Did a neighbor complain? I don't have anywhere off-street you could put it, but if it's got valid tags, my neighbors are pretty chill about that sort of thing and you could park it over here for a bit perhaps. If only I had my Bronco up and running for towing purposes...

'92 Bronco Build Thread - '95 MAF 5.0, H5 axle code, York OBA, 3G alt, custom jump seat console, flomaster steps/sliders.
http://www.supermotors.net/28006
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post #16 of 70 (permalink) Old 04-13-2017, 09:13 PM
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I had a code enforcement officer drive by my house and issue me a warning BEFORE anyone complained. My car was on jack stands with a car cover over it. I pulled the jack stands out and they took the warning away. Call the city and ask them what you can do since it's not junk, just a work in progress.

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post #17 of 70 (permalink) Old 04-26-2017, 03:26 PM Thread Starter
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No idea if a neighbor complained or if it was the city. Although some new neighbors just moved in a month ago across the street from me. Guess it's ok people steal shit, siphon gas, and hit two of my vehicles. I can only imagine they didn't like looking at it.

I decided to keep my Bronco and I moved it to my brothers house. I'm planning on moving it back when I finish building my shed. I'm building a shed to clear out my garage so I can put the Bronco in it. I scrapped the Super Duty frame and kept the axles.
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1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #18 of 70 (permalink) Old 04-26-2017, 05:03 PM
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No idea if a neighbor complained. Although some "picky" neighbors just moved in a month ago across the street from me. Guess it's ok people steal shit, siphon gas, and hit two of my vehicles. I can only imagine they didn't like looking at it.

I decided to keep my Bronco and I moved it to my brothers house. I'm planning on moving it back when I finish building my shed. I'm building a shed to clear out my garage so I can put the Bronco in it. I scrapped the Super Duty frame and kept the axles.

I think I'm going to make some "art" so my neighbors can enjoy the new view.

Heck yes! Glad its still alive.

I suggest making something like this:

1995 BMW 540i
'79 SHTF Daily Build
1997 Toyota 4Runner (locked) - Sold but close to me
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post #19 of 70 (permalink) Old 05-15-2017, 10:04 AM Thread Starter
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Haven't done much recently. Found a new job so I've been a little busy with that. Haven't finished my shed so I've been working on it at my brothers house. Pulled the engine/transmission/tcase this weekend. Hopefully going to start my front axle swap this week.


1989 Bronco 6bt Cummins Zf5 Super Duty axles build thread
1989 F350 6bt Cummins ZF5 4wd
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post #20 of 70 (permalink) Old 05-15-2017, 11:49 PM
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Good luck brother! I. Love. My Cummins swap
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