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disciplerocks's 89 Bronco II Build Thread

162K views 104 replies 4 participants last post by  disciplerocks  
#1 · (Edited)
Current parts and mods

4.0 OHV from a 94 Explorer
A4LD/5R55E hybrid, rebuilt, shift kit, oversized pan
1354/1354 doubler
Explorer front driveshaft for rear
Explorer Sport rear driveshaft for front
High pinion dana 44, Helical LSD, 4.56 gears, Warn lockouts, Single spindle nut setup, Poly bushings
Full width 31 spline 8.8, trussed, spooled, 4.56 gears, disc brake swap
F250 brake master cylinder
2" drop shackles and stock Ranger 2" lift blocks
Repacked Explorer leafs
6" Rough County XJ coils
35" Baja Claws
9k winch
130 amp alternator
On board air

Exo in process

Dana 60/Sterling swap in process

Wheelbase - 99.75"
Crawl ratio - 69.27:1
RTI - 924

So here she is, my $700 B2.

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Budget lift
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Real lift
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Broken D28, and the new D35 with 3.73s
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Old 7.5 and new 31 spline 8.8 with L/S 3.73s
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Old steering with lift
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New ZJ steering setup
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Stonecrusher radius arm extentions
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Sliders
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New rear bumper
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New front bumper
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Diff protector
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More to bumper
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4.0
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4.0 in its new home.
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Idle video


Half door
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New tires
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Caught on fire
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Installed high lift
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F250 shock towers
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New D35 and 8.8 with 4.56s already installed
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Aussied the front, welded the rear
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Fenders cut for flexy XJ springs
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D35 maxed out
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And the flop
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F250 master cylinder
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New steering
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Tube fenders
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And then came the doubler
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First trail after doubler I blew both hubs and cracked a lift bracket.
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So I came across a high pinion D44 with 4.56s already installed.
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One day solid axle swap
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Then came the full width 8.8
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Welded tubes, installed an Explorer disc brake setup with redrilled rotors, and installed a mini spool
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Then the FM146 couldn't hold the 4.0 anymore. Rebuilt A4LD with oversized pan, shift kit, and 5R55E drum, pump, starter and bellhousing.
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Auto ready to go in
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New 8.8 in, moved back 3"
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Fender cut
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#4 ·
That post took awhile to make! Glad I saw this thread. I always had wondered what your bronco looked like. I hope we turn the jeep we have into a trail rig...otherwise I always wanted a Bronco.
 
#7 ·
Picked this up today. Its some kind of helical l/s out of a Dana 44 Jeep rear with 4.55 gears. It does not look like a stock Jeep unit. It looks like a Detroit, but not exactly.
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#9 ·
Did you get it done? I just got finished rebuilding John's front 60 (again). His pinion was loose again. I found out who ever set up his gears the first time didn't do it right. Luckily its just his trail only truck and didn't have high miles or high speeds put on it. The last guy who changed his yoke messed up the threads on the pinion. Turns out they replaced the nut with the wrong one. John got another nut but was the wrong one as well. I ended up cutting about 3 threads off the pinion (they would have chewed up any other nut going on) and re-installed everything with a new, correct nut. He will need a new ring and pinion next time its taken down. Gear pattern is way off, but John decided to just run it as it is, which will likely be 2 or 3 more rides, and he will be getting a new R&P as well as an E locker. We also found it has GM spindle nuts. So a set of Stage 8's are on the list as well....

SVT
 
#10 ·
I will be finishing it up today. I'm running to the new Liberty yard this morning. Had a buddy tell me there is a Chevy 44 with factory drive flanges on it. So I'm going to go nab them.
 
#12 ·
Replaced the inner axle seals while I was in there. No more fluid pouring onto the ground everytime I am off camber.

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#24 ·
Time for an update. Picked up a Dana 60 today. Been wanting to go 8 lug for a while. After finding this, it made it official. Its out of a 99 Dodge dually. I will have to get a one piece passenger shaft to delete the CAD. And I am pretty sure I am going to convert to leaf springs unless I find a deal on air shocks. Next step is to find a Sterling for the rear, and then the 44 will be going in my F150.

 
#25 ·
This is my plan for the CAD front axle. I have seen write ups on how to make your own kit with a throttle choke cable. This way I can weld the front, save some $$, and still be able to disconnect the passenger side to help turn. And I will be able to do it from inside the cab.

http://www.4x4posi-lok.com/app_dodge.html
 
#26 ·
You will regret going leafs in the front, its like riding on bricks, stupid stiff ride. Stay coil spring. If you wait long enough, my airshocks will be going up for sale when I redo my setup...

SVT