MS88Bronc's new build the "Tennessee Warden" (96) - Ford Bronco Forum
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  • 9 Post By MS88Bronc
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post #1 of 12 (permalink) Old 06-30-2018, 09:03 PM Thread Starter
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Join Date: Jun 2016
Location: SE Michigan
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Bronco Info: 96 XL, 5.8L, E4OD, 6" lift, 4.56 gears, 35" GY MT/Rs, front locker, rear LSD, rear disc conversion
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MS88Bronc's new build the "Tennessee Warden" (96)

Hello there guys...

After being forced to sell my old '88 and fall into the shadows for a bit, I have regained my footing and hopped back in the saddle. I found a pretty clean, rust-free, '96 Bronco XL near my new home in SE Michigan. It is a former Tennessee Wildlife Resources Agency fleet truck and spent all but the last couple years of its life in TN. Knowing it was a state gov't truck, I feel pretty confident in its maintenance schedule for most of its life. I am the third owner, and the guy I bought it from only put about 6000 miles on the clock. He put a lot of work into it, and did a pretty good job at most of it, from what I can tell. Here are the stats of it when I purchased it:

- 1996 XL model
- 5.8 L with E4OD/BW1356 t.c.
- 8.8 limited slip and TTB Detroit-locked D44 with 4.56 gear ratios
- Warn lockouts
- 15x10 black wheels (unknown brand)
- 35" GoodYear Wrangler MT/R Kevlar
- Rear disc brake conversion
- Stainless braided brake lines
- Front and rear custom fabbed off-road bumpers with swing-out spare carrier
- recessed off road lights in front and rear bumpers (not wired yet)
- Custom fabbed rock sliders with step bars
- Mastercraft suspension racing seats
- 5.5" JBG SuperFlex suspension lift with extended radius arms with Deaver prog coils and
leafs
- Pioneer head unit with wireless remote
- New door and panel speakers of unknown brand
- New stainless 3" exhaust from the stock Y-pipe back, new high-flow cat, and Flomaster
muffler with exit behind the wheel

It runs well, and a fellow FSB member came by my house the other day and helped me reset the PSOM, so it should run even better on the road next time i take it out.

So without further ado - here she is:












MS88Bronc
Don't be fooled by the name,
1996 XL with 5.8L/E4OD/BW1356,
4.56 gears with lockers

-->My Build Thread<--
***GO NOMINATE AND VOTE FOR FULLSIZE OF THE MONTH HERE!!***
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post #2 of 12 (permalink) Old 06-30-2018, 09:17 PM
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Bronco Info: 84' 351, c6, 4" RANCHO
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nice!
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black hat backwards
LETS ROLL
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post #3 of 12 (permalink) Old 06-30-2018, 09:35 PM
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Location: Sherry Wi.
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Bronco Info: 1996 Bronco 348 10.5.1 E7 Ported 88 Gt roller cam retarted 5 Shorty Headers 3" after cats
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Some one spent some money and lost interest to your advantage.
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post #4 of 12 (permalink) Old 06-30-2018, 10:16 PM
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Nice score!!

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post #5 of 12 (permalink) Old 07-01-2018, 11:08 AM
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Bronco Info: 1996 EB, 351w, stock-ish. 1981 custom 351m, long gone.
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I like the nickname
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post #6 of 12 (permalink) Old 07-01-2018, 05:24 PM Thread Starter
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Location: SE Michigan
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Bronco Info: 96 XL, 5.8L, E4OD, 6" lift, 4.56 gears, 35" GY MT/Rs, front locker, rear LSD, rear disc conversion
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So one of the first things I want to do is clean up the interior and make it look nicer. It’s an XL with no frills (hand-crank windows, manual locks, no center console, no speed control, no tilt column, etc.), but it does have A/C that blows cold, a strong blower motor, rear window that rolls up and down beautifully, rear window defrost, and a working windshield washer and strong wiper motor.

The bedside panels in the back seats/cargo area, at some point, were discarded - maybe got wet and soggy, were damaged, who knows? Anyway I thought about and thought that maybe I would source some XLT or EB rear panels from a JY somewhere. Then I thought to myself, “self, you’re pretty good with your hands and were a Boy Scout many moons ago - make your own!”

So I cleaned out the back cargo area, vacuumed it out with the help of one of my boys, wiped all the sides and floor down with Simple Green.








Then the process to make new bedside panels started. After several trial and error fits, a cardboard template was make for a new passenger side panel.


I then went to the local JoAnn fabric store and picked up some leather-grained beige and green vinyl. I started designing the bedside panel covering material. The measurements:

...and the design:


I get some free time and start in on it (borrowing my wife’s sewing machine!).






Now to pick up some thin board to wrap this around. Stay tuned.


MS88Bronc
Don't be fooled by the name,
1996 XL with 5.8L/E4OD/BW1356,
4.56 gears with lockers

-->My Build Thread<--
***GO NOMINATE AND VOTE FOR FULLSIZE OF THE MONTH HERE!!***
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post #7 of 12 (permalink) Old 07-01-2018, 06:30 PM
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Bronco Info: '90 xlt 351w E40D Truetrac I GOT ROLLER ROCKERS !
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You fukk up that table and she will hand you your NuTz in a different sack !!!

"I got roller rockers" DAMMIT!!
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post #8 of 12 (permalink) Old 07-01-2018, 07:38 PM
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Bronco Info: 1978 Round headlight, haven’t decided T19 9" R, 44F/1991, 445 FE, t19, 205, Dana 60/70, MAF, Moet's
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Wow I want picture of the furnature the piece behind the table looks like quarter sawn veneer nice! The side panels look great too, I need to make some myself as everyone ends up getting hacked for crappy speakers.
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Last edited by 445 FE Bronco; 07-01-2018 at 07:42 PM.
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post #9 of 12 (permalink) Old 07-03-2018, 11:50 PM
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Bronco Info: 1996 Bronco 348 10.5.1 E7 Ported 88 Gt roller cam retarted 5 Shorty Headers 3" after cats
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It doesn't sounds like I'm the only Guy that knows how to run a sewing Machine..
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post #10 of 12 (permalink) Old 08-23-2018, 09:20 AM Thread Starter
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Join Date: Jun 2016
Location: SE Michigan
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Bronco Info: 96 XL, 5.8L, E4OD, 6" lift, 4.56 gears, 35" GY MT/Rs, front locker, rear LSD, rear disc conversion
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MS88Bronc's new build - the &quot;Tennessee Warden&quot;

So while I was doing all this "seamstressing" I knew I needed to do a coolant flush, because the coolant looked like the "muddy Mississip." So that happened next.








I got the windshield replaced next, as it had huge cracks in it, all the way across.








I then painted up the trim pieces for the back cargo area, in preparation for the new bedside panels.







To build the bedside panels, I picked up some 1/8" hardboard (not very hard IMO, but I don't want to add a ton of weight either), and I traced out the cardboard template and started cutting.










Then, the foam padding and custom-made panel covers!











Still working on fitting it right, speaker grilles, and trim, but it'll be done soon!



Also, got new window seals, installed new axle pivot bushings, and got a fresh alignment.












Got a new dash mat to cover and protect the dash.







MS88Bronc
Don't be fooled by the name,
1996 XL with 5.8L/E4OD/BW1356,
4.56 gears with lockers

-->My Build Thread<--
***GO NOMINATE AND VOTE FOR FULLSIZE OF THE MONTH HERE!!***
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post #11 of 12 (permalink) Old 08-23-2018, 09:37 AM
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Good job man!! That thing is comming along great.

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1994 Bronco xlt 5.8
2015 F350, 4x4
2018 Dodge GC (That's what she wanted)
2012 Toyhauler
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post #12 of 12 (permalink) Old 08-23-2018, 10:14 AM Thread Starter
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Join Date: Jun 2016
Location: SE Michigan
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Bronco Info: 96 XL, 5.8L, E4OD, 6" lift, 4.56 gears, 35" GY MT/Rs, front locker, rear LSD, rear disc conversion
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I'm not sure how I could forget to add this, but I had to replace the right front wheel bearings before the shop would align it, so aided by fellow FSBer Sackman9975, we did it. The bearings were toast, and come to find out the Warn lockout was falling apart when we removed it - luckily I had a spare! Additional note: due to the bad bearing, the ABS tone ring was rubbing the ABS sensor, and jacked that up too - so my ABS light stays on (at least that's what I think is causing that - could be the VSS too, not sure yet). Here's the spindle after removing the wheel and hub (and pieces of bearings).


We also found out that the PO had tried to use a one-piece grease seal on this 96, which should have been a two piece seal - I only had a one-piece seal in my parts box to do the swap. Since sackman had a spare spindle shaft and rotor from a 95, he graciously let me have it to install, and I gave him my old rotor and spindle, to go to the scrap yard. We discovered this discrepancy after we went for a test drive and the hub was scorching hot after a 15 minute drive. We returned and pulled everything off again to discover the new one piece seal we installed (the wrong one) was destroyed. We had to get a little creative to pull the hub back out, since it was tighter than it should have been going in.

Presenting, the custom Warn hub puller!....


BigBlue 94, dash_cam and SRWillis like this.


MS88Bronc
Don't be fooled by the name,
1996 XL with 5.8L/E4OD/BW1356,
4.56 gears with lockers

-->My Build Thread<--
***GO NOMINATE AND VOTE FOR FULLSIZE OF THE MONTH HERE!!***
MS88Bronc is offline  
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