1992 Bronco Eddie Bauer build

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Wilson_Beck

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What's up, I'm looking to do a carburetor conversion and also a E40D to ZF manual conversion on my 5.8. I'm pretty new to anything this big, mainly done repairs and worked on smaller vehicles so I was just trying to figure out all the parts that I would need, average cost for the build and a general overview of the process, Any help or links to related threads are appreciated and please don't tell me to stay with EFI, I understand the benefits, I just want to make it a little more simple.

Thanks

 

miesk5

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Yo Wilson_Beck,

Welcome to the Zone!

For now;

EFI Swap to Carburetor

Source: by BLADE262US, Seabronc & our late buddy here, Justshootme84 via miesk5 at

http://broncozone.com/topic/21208-efi-to-carbhelp/page__gopid__111080&

EFI Swap to Carburetor; "...It's actually a pretty simple swap. Basically all of the computer/sensor stuff can be scrapped. You won't need any of it. What you will need...a carb (obviously), a new intake manifold, a new distributor, an ignition control box (like an MSD or Mallory box...I've had good luck with MSD 6A boxes so long as they're not exposed to significant heat), and a carb fuel pump. The EFI pump is way too strong for a carb so you'll need something like a Holley carb electric pump. The ignition stuff is pretty straight forward, but for a working tach you'll need to find the tach wire in the ignition wiring harness and attach it to the positive side of your coil. I know in Mustangs this wire was green with a yellow tracer. It may be the same in your Bronco, but it's good to double check. For a carb I would use something like a Holley 600cfm double pumper or a slightly smaller Carter carb. I had a 625cfm Carter on my Mustang before I switched over to a turbo'ed EFI setup and it was a little too much for the motor. One point worth stating is that if you have an automatic transmission that has overdrive (like an AOD), you'll need an adapter for the TV linkage on the transmission since AODs never came on carbed motors. One is (or at least used to be) available for Holley carbs through Sacramento Mustang, but they retail for just under $100. If you have a 3 speed like a C4 then all you'll need to do is make sure the carb has a kickdown linkage. Mind you I got my old Carter to work with my AOD...but I think that was just sheer luck. Hope this helps...let me know if there's anything else I can clear up for you..."

Source: by Steve H

S5-42 Swap from E4OD in a 95

Source: by Broncobabe (Miss Kitten) at http://web.archive.org/web/20110102052132/http://adventureoffroad.ca/phpBB3_1/viewtopic.php?f=12&t=1840

S5-42 Swap from E4OD Parts List in a 94 as of 04-28-2003

Source: by Franklin (Jeff)

"ZF S5-42 Ford/Junkyard Used $600

Rebuild ZF: seals, bearings, synchros LP Gear $500

Flywheel E8TR-AA Ford/Junkyard/Call Franklin

New $406

Used $40

Franklin $185

Flywheel Bolts MRG 912 Heinz Bros $8.75

Tranny Bolts 2- 1" Shorter than stock Heinz Bros $2.00

Pilot Bearing AutoZone 7.99

Internal Clutch ***** YL5Z7A5008AA Ford $66.65

Hydralic Hose F3TZ-7A512-A Ford $42.95

***** Cylinder Ford $62.29

Internal Clutch ***** Bolts Interstate Bolt $1.00

Clutch Disc CEN218226 Heinz Bros / Centerforce II $72.25

Pressure Plate CENCFT360049 Heinz Bros / Centerforce II $150.66

PP Bolts 3/8/18-1" Heinz Bros $5.95

Pedals 92-96 F150/Bronco J&T Automotive Used $35.00

Floor Pan 92-96 F150/Bronco J&T Automotive Used $20.00

ZF Shifter/Boot 92-96 F250 w/351 J&T Automotive Used $35.00

Driveshafts: +63mm in the rear, -63mm in the front

Need to use a wire jumper to bypass the neutral safety switch.

Phone #'s:

J&T Automotive 1-800-274-8090

Heinz Bros 1-704-872-8081

These prices will probaly be cheaper than most can find because I am running this through Corley Body Works, my brother-in-law's shop. But it will give you a good ball parkz"

S5-42 Swap Info & pics from E4OD in a 90

Source: by Banshee_boy_01 at http://www.supermotors.net/clubs/superford/vehicles/registry/10198/65313

...

S5-42 Tips; "...There are three rubber plugs on top of the transmission that leak fluid only when the truck is in motion so when parked there will be no tell tail signs of a leak. You can replace the plugs yourself or take it to the dealer and have them check it for fluid lose and replace the faulty plugs but it's not cheap. Thing is, the seals are going to fail and if caught to lateas in my case cost you a bundle. Another set back for theback yard mechanic is the bleeding of the ***** cylinder. If not done exactly correct your clutch will not work no matter how much you bleed it. Bleeding the ***** cylinder, which is inside the transmission and not on the outside like older ones, relies more on gravity to bleed and not pumping. It's just a big pain in the ass actually and it will test your patience.

Source: by WooleyBugger

Bbl

 

miesk5

96 Bronco 5.0
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Yo,

S5-42 (7003) Parts Break-Out Diagram, Service Tips & Troubleshooting Guide; 07-03B-17 1994 Econoline / F-150, F-250, F-350 / Bronco / F-Super Duty Powertrain, Drivertrain Aug 1993

Source: by Ford via

http://www.thedieselstop.com/faq/9497faq/download/S5-42.pdf

Yes Bronco... is it a typo by Ford... or was it planned to be part of the 94 model year?

S5-42 Swap from E4OD pics in a 90 5.8

Source: by My90Bronco (James, Switch) at http://www.supermotors.net/clubs/superford/vehicles/registry/4685/21796

S5-42 Swap Info & pics from E4OD in a 90

Source: by Banshee_boy_01 at http://www.supermotors.net/clubs/superford/vehicles/registry/10198/65313

...

Next time, please fill out your Signature with year, engine size, transmission type, transfer case type (manual or electric shift), locking hub type (automatic or manual) info & major mods such as a Lift, etc. for better responses.

Click your name in right black panel in upper right;

In pop up,

Click, My Profile

Click, Edit My Profile in right side black panel

In left panel, Click, Edit Signature

Enter info

Click, Save Changes

...

To post a pic from your PC, TABLET, etc., just below the reply box in lower right corner, click More Reply Options

Screen will change

See Attach files

pick out the pic

Click Attach This File

or click, Try our advanced uploader (requires Flash 9)

...

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Here are some wiring diagrams (partial, 86 through 96) and Technical Service Bulletins, (80 through 96) @ http://www.revbase.com/BBBMotor/Wd

Can you write up your swap with pics here?

 

MaximusBronk

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Wilson,

Read the "1990 EFI to Carb Conversion" topic that I started months ago.  I did the conversion, but stayed with the E4OD tranny.  In order to use the E4OD, I installed a "Quick 4" controller.  I have pics of the controller with a tuning laptop in the topic.  You are allowed to program as many as 4 different tranny performance profiles in the Quick 4 controller, and easily select which one you wish to run on (Performance, Off Road, Cruising, Etc).  If you have any questions on the swap, feel free to PM me.  There are a number of things you will have to consider, such as a carb camshaft, fuel pump, and even a higher energy starter, etc.

Rod

 

gunnyP

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Wilson,

I used Rod's experience as a guide to convert my 92 EB to a Carb'd no smog motor. I used a crate engine with a significant HP/Torque upgrade and a Vacuum MSD ignition. I also used the Quick 4 transmission controller for my E4OD (I used a OH'd unit from Monster Transmission because of the HP/Torque upgrade). I put a pressure regulator for the fuel to the carb and kept the pump in the fuel tank (put a pressure return line in). The fuel lines are a bear... Ford uses their own 'SpringLock' connectors that I could not find replacements for. If you cut the line DO NOT use a grinder. I put in an electric dual fan/variable speed cooler for the radiators. I put in a Lokar throttle cable and still haven't solved the cruise control bracket issue. 

It's not a simple conversion, but if you go about it methodically you'll have a great truck! I love mine!

gunny

 
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MaximusBronk

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How did your Quick 4 programming go?  If you dont mind, I would like for you to download the shift curve and email it to me.  I am trying a few different curves (you can pre-program up to 4 of them, and select as necessary)

Rod

 

MaximusBronk

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Post us some pics of your engine, and maybe one of the Quick 4 module installation in the cabin?

 

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