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Discussion Starter #1
Hello All,

I am replacing all of my body mounts with energy poly bushings and need some help putting the new parts in the correct order.
My '94 XLT Bronco was wrecked at some point in it's life and I can tell because the passenger fender, radiator core support, and headlight support are all aftermarket junk.
Thus I am not sure if they reassembled it correctly.

I found a diagram on LMC and was wondering if the part where it is faded out gray is where the radiator core support is sandwiched into place. Between #8 & #9 is where the core support goes?

Also I am not seeing the number #8 spacer in the new kit nor originally installed. Guess I need to order some shims?

Also removing the passenger side core support was a PITA!!!! I had to hold the top bushing down with a vice clamp to get the corroded bolt out, since the hexagon was rounded on the bushing.

Thank you all!
165157
 

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Were you able to get the body mount hardware kit? I keep looking in JBG and the description says out of stock with no ETA. I wanted to replace all that hardware and bushings so the body is sitting correctly on the frame before i start hanging sheet metal and lining things up. And you, you are correct that faded area is where the core support falls in.
 

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Discussion Starter #3
Were you able to get the body mount hardware kit? I keep looking in JBG and the description says out of stock with no ETA. I wanted to replace all that hardware and bushings so the body is sitting correctly on the frame before i start hanging sheet metal and lining things up. And you, you are correct that faded area is where the core support falls in.
I bought the hardware kit from energy suspension parts, however they are special order 3-6 weeks. I have not received the hardware kit yet, I only have the bushings.
 

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I bought the hardware kit from energy suspension parts, however they are special order 3-6 weeks. I have not received the hardware kit yet, I only have the bushings.
Thank you, I will look into this. My bronco has been on hold because I really didnt want to start going after it unitl it was sitting properly on the rails. The bushings are all collapsed and the hardware is all corroded.
 

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I went on that website you were talking about, and comparing it to the one sold on JBG I am a bit confused. The kit on JBG is $100 more and appears to have more pieces. What is the kit from energy missing from the other kit?
 

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Yo 901,
For now, until my isp isnt erratic;
Parts Break-Out & Locations (& Bolt Sizes) for 94 (other years are similar) w/Nomenclature; "Check out View Z (lower R). It's not totally accurate because it omits the thick spacer, and there should be another washer between the Nut & the Spacer on top of the core support..."
165199

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Body Mounts for 1994 Bronco ('80-96 similar; F-series cab mounts similar)
IF THE IMAGE IS TOO SMALL, click it.

The rear bolts (view V) are 7/16"x14(NC) 6.5" long threaded 2.5" with a 5/8" head with large integral washer.
The 6 identical bolts are 7/16"x14(NC) 3.75" long threaded 2.5" with a 5/8" head with small integral washer.
The front bolts (view Z) are M12x1.75 100mm FULLY THREADED w/15mm head & small integral washer.


Note that the necked portion of the upper sleeve (part of the upper absorber) is designed to lock onto the lower sleeve (flared assembly nut) to hold the rubber in place on the frame on the assembly line. But it funnels dirt & water in around the 2 parts & the bolt threads, usually rust-welding them together. So the longer they're soaked with penetrating oil before disassembly, the more likely they are to come apart.

Once the bolt is backed out a few turns, spray more penetrant down into the upper sleeve to rinse the rust off the threads, and use a hammer & drift on the bolt head to separate the sleeves.

The core support mount (views U & Z) is different, and the bolt threads into it from below. It's virtually impossible to separate them, or even to unscrew the bolt. They usually have to be cut apart and replaced.

See also:
. . . . . . . ...by Steve

Removal Tips in a 94 (pics are gone)
Source: by Bill Von V (94bronco) at mybigbronco.com via web.archive.org @ Body lift Process and Pictures.

Replacement Info & Sources; "...replaced mine as part of my restoration project over the last year+ . All I've got to say is that it was a ROYAL PITA. To replace the front ones you need to have them all loose so you can raise the body far enough to put the new mounts and associated hardware in. 5 of the 8 were so rusted inside the tube that I couldn't simply soak them as previously mentioned. I ended up using a carbide saw blade, (one with diamond grit along the edge), for a sawzall to cut the tubes and that took forever because you are cutting bolts that are a number 8 hardness. If you are going to replace any, replace them all. Use the polly mounts. Make sure you get the kit for a Bronco and not a F150. The diagram in the LMC Truck shows the wrong poly mount for position 2. That is the poly mount for a F150. In fact the one that goes in that position, including the associated hardware, is the same as position 3. As far as bolts go, the bolt kit from Bronco grave yard is much too long so just go out and get the ones listed in Meisk5's first response. From the LMC Truck catalog you will need the following hardware http://www.lmctruck....ll.aspx?Page=36 6 of #28, 6 of number 31, 2 of number 18, 6 of number 27, ( I didn't use the other numbers as they are the same part number, what I did list skips the hardware they show for position #2 and gets you the correct part). LMC truck has been notified of the diagram error for position 2, which you can see in the second diagram of Miesk5's original post. The Bronco poly kit from Bronco Graveyard http://broncograveya...=body+mount+kit , number 33090 or 33092 has the correct poly bushings including the radiator support bushings. Do not waste your money on their hardware kit as it has bolts that are way too long (part number 33100). Get the hardware from LMC Truck that I previously listed, with the exception of the rear mounts, I went to LOWES and got # 8's from them. I don't know if LMC has the correct length bolts, because by then I had so many useless bolts, I didn't want to risk getting another useless set ..."
Source: by Seabronc
 

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Discussion Starter #8 (Edited)
Oh snap you are right. Looks like the kit I bought is missing the core support hexagon pieces. Maybe you have to reuse them? I’m going to do some digging....

EDIT:
It looks like the difference between the JBG and the Energy Suspension kit is that the Energy kit lacks the two larger "sleeves" and these core support threaded "hexagon" sleeves. Ford part number E0TZ-1000396-A . Looks like you either have to reuse these or find them online, which they are not cheap...... JBG has the best deal but with no ETA that is worrying. I need this kit here: 1980-1997 Ford Bronco & F-Series Truck Radiator Mounting Kit-Broncograveyard.com

EDIT2: Looks like LMC has them? #6 and #2 Body Mounting
 
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