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66-96 Ford Broncos - Early & Full Size


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About miesk5

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    Coronado, CA
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    Fishing, swimming, underwater adventures, & fast Fords.

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  1. Yo Dave, Project M.P.G. in a Centurion 460; miesk5 Note, Results are Comparable to Tests in other Ford Engines. Source: by performanceunlimited.com @ FOUR WHEELER Magazine's Project M.P.G. Some use this information while others write that the results are not achievable. COLD air intake - insulate air intake from grille entry area to throttle body. Air Tube & Box Insulation pics in a 94 5.0; Ken used Reflectix Insulation, avail @ Lowes. etc. ST16025 - 16" x 25 feet. miesk5 Note; Ken installed the K&N® & removed the cold air intake tube that runs to the top of the radiator; but he could have installed the intake tube section later. Source: by Ken B (Kenny's 94) Is Check Engine Light ON while driving? Check Engine Light (CEL) comes on when the electronic engine control system is not working properly. The check engine warning indicator comes on briefly when the ignition switch lock cylinder is turned to ON, and should turn off when the engine starts. If the check engine warning indicator does not come on when the ignition switch lock cylinder is turned to ON or if it comes on while the vehicle is moving, the system is malfunctioning If the CEL does not light up at all when starting it; then suspect that bulb is burnt-out or loose, socket was damaged by PO or shop, etc. or someone removed it, which does happen, unfortunately. Try a Self Test for Diagnostic Trouble Codes (DTC)s by my pal, BroncoJoe19 Code Reader..... - 80-96 Ford Bronco - Ford Bronco Zone Early Bronco Classic FullSize Broncos A helper is good to assist in reading Codes; best is to take a cell fone vid and replay it. Some basics; Visual Check 1.Inspect the air cleaner and inlet ducting. 2.Check all engine vacuum hoses for damage, leaks, cracks, blockage, proper routing, etc. 3.Check EEC system wiring harness for proper connections, bent or broken pins, corrosion, loose wires, proper routing, etc. 4.Check the Powertrain Control Module (PCM), sensors and actuators for physical damage; IAC, TPS I see was replaced, etc.5.Check the engine coolant for proper level and mixture. 6.Check the transmission fluid level and quality. See E4OD Fluid Condition Check Below) 7.Make all necessary repairs before continuing 8. Check headlights The engine temperature must be greater than 50° F for the Key On Engine Off (KOEO) Self-Test and greater than 180° F for the Key On Engine Running (KOER) Self-Test. Run it around to heat the engine up and shift thru all gears including Reverse. Make sure A/C is off and transmission is in Park (automatic); or in Neutral for a Manual & release clutch. Turn off all accessories; radio, lights, A/C, heater, blower, fans, etc. (close driver's door) Then turn off engine and wait 10 seconds. Do KOEO test First You should see 3 digit code (s) if any Post Code(s) here according to: KOEO & KOER *** Following applies to California, etc. CALIF REFORMULATED GAS (CARFG) - SERVICE TIP TSB: 96-10-7 very minimal mpg loss. FUEL ECONOMY - EXPECTATIONS VS ACTUAL 99-26-9 for 91 F250 Revised *** Fuel Saving Tips I have always factored in any cost to improve MPG in the overall $ "savings". Free: Reduce weight of the Bronco and tools, accessories and ... passengers; driver's get a pass; also, grille guards, side steps, etc. Ensure that brakes are not dragging Driving style/ light foot - Foot on Pedal too much while accelerating and high speed driving over speed limit proper tire pressure - Under inflated tires Increase rolling resistance 1-2 mpg; Dirty air filter Causes excessively rich fuel/air mixture 2.0 mpg; Worn spark plugs Cause inefficient combustion, wasted fuel 2.0 mpg; Worn O2 sensor Unable to detect and adjust air/fuel mixture 3 mpg (not it your year); Dirty or substandard engine oil Increases internal engine friction 0.4 mpg; Loose gas cap Allows fuel to evaporate 2.0 mpg Potential loss in fuel economy if all of the above were neglected 11.4 mpg Add them all up and you get yaris mpg. Lol Check Timing Try Sixlitre Tune-Up @ ignition upgrade and timing bump (no 56K) & more Items that Cost $: alignment tune-up. plugs - pull and check/re-gap, replace if nec, same for plug wires (check for insulation cracks, and resistance (more on this later), distributor cap and rotor brake parts - always $ WELL SPENT I use Ford Motorcraft parts via AMAZON; they are VG at delvy and esp pricing; I bought a $150.00 DPFE Sensor (not incl. sales tax) for $50.00 with free shipping and no state sales tax; same for the IAC sensor. Some buy from a Ford pn on-line or local parts stores that list the Ford PN, but the ads show the PN as a reference only and the supplier may be a company off-shore. other than a Ford supplier. *** High Quality Motorcraft TFI Ignition Coil Attributes Source: by SeattleFSB (Seattle FSB) @ MSD 8227 coil problems Many Bronco owners shop for an ignition coil by looking for the highest voltage available. But I venture to say that there is much more to look for in achieving both a quality ignition system and saving money in the long run. For clarification, it takes approximately 10-14,000 volts to initiate the spark across the OEM spark plug gap. After the initial arc, the voltage required to sustain the arc is much less and drops off significantly. So while you may have a 48,000v coil you can't actually get that across the plug. The extra power becomes reserve voltage which compensates for worn plugs, increasing resistance in wires and carbon fouling. This increased stress can require an additional 1-5000 volts. Fact is a higher voltage coil does not work any better, it just lasts longer due to having a higher reserve reducing heat. You cannot push more than 20,000 volts across a spark plug without bad things happening. If you were to try you would see arcing down the side of the plug, across carbon buildups at the electrode end and out any weak points in the wire insulation and connections. The bottom line is the ideal coil output required for normal applications is about 30,000 volts. So no, your coil does not need to be 48,000v for proper ignition. The benefit would be in having enough reserve to compensate for high resistance due to a worn or altered ignition system. This is why the Sixlitre Tune recommends a 48,000v coil and larger spark plug wires – to compensate for a substantial increase in resistance from larger than specified spark plug gaps. You are adding resistance as the spark attempts to reach ground. This in turn causes the plug wires to break down and decreases the service life of the rotor, distributor cap, spark plugs and increases the chance of spark scatter within the Distributor Cap. Think about it, you are setting your spark plugs at a maximum gap even before wear. The higher voltage coil does not reduce stress and wear on your ignition system; it only compensates within a larger margin and then ultimately becomes dependent upon the quality of construction for survival. When opening up your spark plug gap from factory specifications you must be prepared to check your secondary ignition system annually, as opposed to about 40,000 miles with a stock vehicle, or risk performance decreases down the road. With that being said, IMHO the Motorcraft DG470 TFI Coil is one of the most dependable 48,000v TFI Coils on the market. This is largely due to the quality in design, testing and construction. I have personally had many dependability issues with other imported TFI Coils, such as MSD. Where a Motorcraft Coil has lasted 15 years, I have went through three MSD coils in five years. Your purchase of a TFI Coil should not be totally dependent upon the voltage, but strong consideration should also be made regarding the contruction attributes listed below: Motorcraft TFI Ignition Coil Attributes Insulation - Multiple coats on the primary and secondary windings to ensure no internal arcing Radio-Frequency Interference (RFI) Suppression - Minimize electronic noise Magnets - Hold strength for the coil to maintain proper energy output Steel - Used in the lamination stack to ensure a consistent magnetic field needed to develop the required voltage Coil Housing - Engineered to withstand extremes in temperature without cracking Low Quality TFI Ignition Coil Potential Issues Rough Running Engine or Misfires - Causing Check Engine Light Fuel Economy and Power Decrease – Costs money and performance Radio Frequency Interference – Affects radio, EEC, sensors, cell phone Pre-Ignition and Detonation – Can cause engine damage Weak Voltage Output – Can cause increase tailpipe emissions..." ***
  2. Yo DL, WELCOME! 1356 Electric Shift Operational Test; "... (engine off, hubs disengaged), crawl under the truck with the transfer case in 2HI, you should be able to grab the front drive shaft and turn it by hand. Also with the hubs disengaged you should see the front axles turning freely. Now engage the hubs and you should not be able to turn the drive shaft by hand. Jack the front wheels off the ground with the hubs engaged, turn the drive shaft by hand, the wheels should turn. The 4x4 light should not be on in 2HI, when in 4LOW you may have a low range light on, (not all trucks have that light) at least mine doesn't..." Source: by Seabronc (Rosie, Fred W) at Ford Bronco Zone Forums ⊙ See 1356 Electric Shift Troubleshooting & Repair - BEST PROCESS! Source: by Dustin S (Dustball, Mellow Yellow, Mr. Laser Boy) Start at "To check if the transfer case motor is actually functioning (because it may be hard to hear it in a noisy shop) attach a voltmeter to A4 and A5. Have someone activate a shift and look for a brief (one second) increase in voltage and listen for the relay to click on, then off. If there is power present, then the control module is trying to run the motor. At this point, unbolt the motor and have someone activate a shift again. If the motor doesn't actually turn, it is malfunctioning and must be replaced. If there is no power to the motor, check both the power circuits again and the sensors. If there is incorrect sensor data, the module won't power the motor." ⊙ Check Transfer Case Motor: 1356 Electric Shift Motor Typical Failures & Prevention; "...Most units fail because of water or mud intrusion. Carefully inspect motor boot or protective coverings. Be sure connector seals can keep water and debris out. Check wiring harness and connector. Replace or repair wiring as necessary. After installation, periodically select 4-wheel drive mode to ensure operation when needed..." Source: by CARDONE® ⊙ 1356 Electric Shift Motor Troubleshooting & Repair (motor travel stops) Source: by Richard C (Bigric, Money Pit) @ https://www.supermotors.net/clubs/superford/registry/4584/21843-2 ● Here are the 1989 EVTM, Emissions & Pre-Delivery Manuals, Partial via mrnewland1 in Google Drive @ https://drive.google.com/drive/mobile/folders/0Bz1eScc6s4raOHd0WlVnMUw4WjQ?usp=drive_web Slow scrolling so download for the table of contents, etc. 1989 Bronco Dealer Brochure @ 1989 Ford Bronco Free registration for some wiring diagrams (86 through 96) and Technical Service Bulletins, (80 through 96), same as by Ford @ BBB Industries- Premium Alternators, Starters, Power Steering Products | TSB's & Wiring Diagrams ● GL! Al
  3. Yo Dave, WELCOME! Congrats and it is great to have another 88 as a spare! Here is the 1988 Bronco Dealer Brochure Here are the 1989 EVTM, Emissions & Pre-Delivery Manuals, Partial via mrnewland1 (similar to 88, see my Note @ end on this page) in Google Drive @ https://drive.google.com/drive/mobile/folders/0Bz1eScc6s4raOHd0WlVnMUw4WjQ?usp=drive_web Slow scrolling so download for the table of contents, etc. Free registration for some wiring diagrams (86 through 96) and Technical Service Bulletins, (80 through 96), same as by Ford @ BBB Industries- Premium Alternators, Starters, Power Steering Products | TSB's & Wiring Diagrams C6 Description & Operation, Adjustments, Diagnosis & Testing (partial), Disassembly & Assembly, Parts Break-Out Diagram, Hydraulic Control System Diagram , Removal & Installation & Specifications @ http://web.archive.org/web/20090530063649/http://www.thedieselfiles.com/Ford/C6 Automatic tranny.pdf 1356 Electric Shift to Manual Shift Swap in a 95 Source: by Shadofax (TheJuice, The Juice, Mark Z) 1356 Electric Shift to Manual Shift Swap in an 87 Source: by Joey S (Nacho, Stokes, Larry, Stoked) at https://www.supermotors.net/registry/3287/16394-2 1356 Electric Shift to Manual Shift Swap in a 90 (Narrative, no pics) Source: by Rade btw, very slow to scroll 5 screw auto lpcking hub swap to Warn® manual & Bearing Replacement w/ Bearing Locknut Torque Settings in a 90; and, Wheel Bearing Locknut Torque Settings for 80-96 MANUAL HUBS, NOT Factory Auto Hubs; Ford Pickups and Bronco; "...Using a lockout spanner (ford # T59T-1197-B or equivalent ) and a torque wrench, tighten the inner bearing adjusting nut to 50 foot pounds while rotating the wheel back and forth and seating the bearing. Back off the adjusting nut approximately 45 degrees. Assemble the lock washer by turning the inner lockout to align the pin with the nearest hole in the lock washer. To lock it, install the outer lock nut and tighten it to 150 foot pounds. Grab the top of the tire with one hand and the bottom of the tire with the other. Move the tire in and out on the spindle. End play should be less than .006 – inch.).." Thanks to 90beater (Topher, Chris)!!!! Source: by 90beater (Topher, Chris) Tire Diameter/Circumference & Air Pressure Differences; "...You will recall that at the beginning of this section, we mentioned that we had made sure that all four tires on our truck were the same size, were worn the same amount, were inflated to the specified pressure and were subjected to reasonable loading. Avoiding driveline windup was the reason for this. Figure 18A shows that tires of even slightly different size roll different distances every revolution. Figure 18B shows that the same effect is true for tires that are the same size but inflated or loaded differently. Operating a 4 x 4 in 4WD with tires of different size or inflation will produce driveline windup, even when driving straight ahead! If the vehicle is being driven in 4WD on dry, hard pavement, the driver will notice drag and may experience the hop, skip, bounce effect as the front or rear wheels release the windup..." in Four Wheel Drive (4X4) General Information, Operation & Troubleshooting TSB 92-1-8 for Bronco, F Series & Ranger (COMPLETE); Includes Electric Shift On The Fly (ESOF) Troubleshooting & Hub Operation; see page 4-6 & Figures Source: by Ford ●●● Note; From Historical Facts on 78-96 Broncos by Trent R @ http://www.angelfire.com/wv/fordbroncos/History.html Excerpt: "...In 1988 Ford again made significant upgrades to the Bronco. New was the M5OD and M5OD-HD manual transmissions. These transmissions featured a .80:1 overdrive and the HD option sported a 5.72:1 first gear. Multi-Port fuel injection (MPI) was added to the 351 cid V-8 engine for 1988. This new motor increased horsepower from 190 at 3,800rpm to 210 at 3,800rpm. The torque was increased from 295 foot pounds at 2,600rpm to 315 foot pounds at 2,800rpm. The introduction of fuel injection also marked the entire motor lineup going to a serpentine belt system. For 1988 the transfer case skid plate was made standard. The only major change in the Bronco for 1989 was the mid-year standardization for the automatic locking hub. Tip/slide front seats were also added as standard equipment to facilitate rear passenger entry..." Cya later here Dave! Al
  4. Yo Billy, YW! For no spark, you'll that site's troubleshooting within the efi link I posted, Here it is https://troubleshootmyvehicle.com/ford/4.9L-5.0L-5.8L/how-to-troubleshoot-a-no-start-1 Then you'll see https://troubleshootmyvehicle.com/ford/4.9L-5.0L-5.8L/how-to-troubleshoot-a-no-start-2 -● Was speed control, if equipped, recall work completed by a dealership? Call local dealer or register and view status @ https://owner.ford.com; or @ https://vinrcl.safercar.gov/vin/ ... have VIN ready. "Summary: ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN. THIS COULD RESULT IN AN UNDERHOOD FIRE." To confirm3 current status, use this guide by jowens1126 @ https://www.fullsizebronco.com/forum/23-technical-write-ups/457065-93-94-96-cruise-control-recalls-repair.html#post6530073 Note that the 93 recall is different than the 94-96 recall 96 Bronco-F-Series Workshop Manual (PARTIAL) via 1996 Bronco/F-Series Workshop Manual 96 Bronco Owner's Guide, Maintenance Schedules & Parts and Accessories by Ford @ https://www.fleet.ford.com/partsandservice/owner-manuals/ 96 Bronco Dealer Brochure @ https://www.supermotors.net/registry/3549/15947-2 ... scroll down 96 Bronco Quick Tips Brochure Excerpts & some Eddie Bauer options @ http://www.supermotors.net/registry/2742/80431-2 Free registration for some wiring diagrams (partial, 86 through 96) and Technical Service Bulletins, (80 through 96) same as by Ford @ BBB Industries- Premium Alternators, Starters, Power Steering Products | TSB's & Wiring Diagrams Register to see most Ford dealer maintenance/repairs done @ any dealership nation-wide @ http://owner.ford.com . Zl
  5. Yo Murdoc, Welcome! Most have moved to Edelbrock 1406 HwyApostle (Jerry) has an 86 351 and installed the 1406; see his installed pics and comment "Edelbrock 1406 Installed and running great" @ https://www.supermotors.net/clubs/superford/registry/3045/11793-2 See Rebuilding & Tuning Edelbrock 1406 Carburetor - Hot Rod Network @ https://www.hotrod.com/articles/rebuilding-tuning-edelbrock-carburetor/
  6. Yo Brian, Welcome! Unfortunately, no supplier nor Ford has the full pan, however MILL SUPPLY, Cleveland, OH, Bronco Graveyard, LMC, NPD ETC have front sections as you probably know by now. We replaced 1/4 rust sections in our 96 with 1/4 panel patch panels from MILL SUPPLY, Cleveland, OH They were primed and of 18 gauge steel - exact fit around wheel well arch and packaged very well for shipping which was very fast. https://www.millsupply.com/auto-body-rust-repair-panels/ford/bronco/1984/?pa 1984 Ford Bronco Front Cab Floor Pan - Right Side Part https://www.millsupply.com/auto-body-rust-repair-panels/ford/bronco/1984/?page=3Number: 90-80-70-RH 1984 Ford Bronco Front cab floor pan - Measurement: 28" x 26" x 6" - Right Side, Passenger Side $31.92 1984 Ford Bronco Front Cab Floor Pan - Left Side Part Number: 90-80-70-LH 1984 Ford Bronco Front cab floor pan - Measurement: 28" x 26" x 6" - Left Side, Driver Side $31.92 Repair in an 86 Source: by BigNorm (Old Desert Goat) see large images and captions @ https://www.supermotors.net/registry/501/18876-2 Repair w/ Rust Bullet® in an 86 Source: by xris More pan repair links in my site @ http://schwimserver5.com/index.php?index=301 ● Here is the 1984 Bronco Dealer XLT/Standard "Catalog" by Gary @ http://www.garysgaragemahal.com/1984-bronco.html Some Fastener Illustrations by Gary @ http://www.garysgaragemahal.com/fasteners--illustrations.html 1980 - 86 Bronco/F Series Carburetors, Chokes & EFI by Gary @ Carburetors, Chokes, & EFI - ???Gary's Garagemahal See more info by Gary. Technical Service Bulletin @ http://www.bbbind.com/tsb-wiring-diagrams-database/ RECALL - SEATS. TSBID: 105674 MFG NUMBER: 83V020000 ISSUE DATE: 1983-02-24T00:00:00 RECALL PROBABLY EXPIRED. GL!
  7. miesk5


    Yo Sam, When in reply mode or starting a new post, touch "Click tocjoose files in bottom left
  8. Yo B, I don't have a source for the harness, so in case it may have to come from a yard queen, but for a YARD SEARCH on-line, I use; https://www.hollanderparts.com A yard that uses Hollander Interchange can search other yards and have it shipped. "...For over eighty years, Hollander has been making the best tool for fast, interchangeable part matches. The new Edition Hollander Interchange contains more interchangeable options than ever before. The Hollander Interchange provides auto recyclers and auto collectors, rebuilders, and others with the easiest and most comprehensive solution for identifying interchangeable auto parts..." See their yard Directory @: https://www.hollanderparts.com/SellerDirectory Can select certain parts[, /B] including some at Canadian yards. Has Vehicle Pics for some vehicles My search just now didn't get resukts for : 1995 >Ford > Bronco > Lights > High Mounted Stop Lamp > Alternate High Mounted Stop Lamp But this search possibly did; Search: 1995 >Ford > Bronco > Electrical > Lamp Wiring Harness > Al"ternate Lamp Wiring Harness ¤ or http://www.car-parts.com/ Can select certain parts Can search by year range, such as 92 through 96 & has best item condition descriptions such as "COVER BAD LEATHER PWR BKT GRY" Has Vehicle Pics for some vehicles incl. interior/dash, back seat, front & rear and engine bay ¤ Bronco Used Part Search @ https://www.partshotlines.com/parts/ford/bronco/ with source, cost, yard and phone # ¤ Concord Spare Parts @ https://www.concord-parts.com/ 732-374-3872 [email protected] ¤ http://www.picknpull.com This is a Company name w/yard locations in various states Can NOT Select certain parts Has Vehicle Pics for some vehicles ¤ B&R Autowrecking, in CA, WA, NV, OR. "We have a fleet of over 60 trucks that deliver to business addresses all over Oregon and Washington. Outside of Oregon and Washington, we have daily shipping services. Contact Us for a quote." "Will ship to their closest yard for $50 flat" by StemCellResearch", 2019 ¤ http://row52.com/Search Can NOT Select certain parts Has Vehicle Pics for some vehicles AND Want a Part? It's Easy... 1. You create a Parts Wanted Listing. 2. Parts Pullers respond with offers. 3. You pick the best one. A Parts Puller gets the parts you need. ¤ For obsolete parts by Ford long version pn: http://www.partsvoice.com/ http://www.rearcounter.com http://www.greensalescompany.com https://nospartsltd.com And by a search function; https://autopartsobsolete.com/truck-ford/
  9. Yo Billy, WELCOME! I assume it cranks over well, if not let us know. If it's a 78 Bronco, see https://jalopnik.com/heres-how-you-diagnose-an-engine-that-wont-start-1717491831 But if efi equipped, see https://troubleshootmyvehicle.com/ford/4.9L-5.0L-5.8L/how-to-troubleshoot-a-no-start-1 Best bet is that you have a mom and pop parts store that you use and they can loan you tools such as spark or fuel pressure test, etc. I prefer mom and pop stores over AZ, etc because they usually have better maintained stuff.
  10. miesk5


    Yo Sam, Welcome! Please post pics and you location.
  11. Yo Shaggy, We'll find out if he asks for it. I can get the routing if he needs it and possible yards that may have it
  12. Yo As Shaggy advised. See this Camper Top Removal w/Tool List, & Security Torx® bolt replacement w/Metric sized bolts (5 8x70mm 1.5 Pitch Metric Bolts & 12 8x45mm 1.5 Pitch Metric Bolts) 92 - 96 Source: by Froggmann (Ken P) Camper Top Trim Parts Break-Out Diagram w/nomenclature; "...78-91 use 17 self-drilling oval-head 1-1/4" phillips screws with captive countersunk washers to retain all the trim pieces. 6 on each long trim, 2 on each short trim, & 1 on the small center joint cover. 92-96 use 5 screws as above for the short trim & cover, 6 color-matched pushpins on each long trim, & 2 plastic pushpins on each rear corner trim..." Source: by Ford via Steve ●□● ➡Was speed control, if equipped, recall work completed by a dealership? Call local dealer or register and view status speed control, if equipped, recall work completed by a dealership. Call local dealer or register and view status @@ https://owner.ford.com; or @ https://vinrcl.safercar.gov/vin/ ... have VIN ready. The affected vehicles were previously repaired using a wiring harness that is not compatible with the vehicle circuit polarity. As a result, the fuse is located in the output circuit rather than in the intended input power feed circuit, and may not offer the intended protection in the event of an electrical short to ground. This could result in an underhood fire. Dealers will install a new wiring harness, or replace the mating electrical component. east302 provided following for his 93 "I found the recall information on alldata...didn't know it was even there so that's a plus. Mine has the updated harness with two fuses instead of one, so it looks like the recall was addressed correctly." Use this guide by jowens1126 @ https://www.fullsizebronco.com/forum/23-technical-write-ups/457065-93-94-96-cruise-control-recalls-repair.html#post6530073 Note that the 93 recall is different that the other years. Here is the 1993 Bronco Dealer Brochure in Google Drive @ https://drive.google.com/file/d/0B-xGWnnLeWl6cGFMTDNNcGprQTA/view 1993 Bronco Dealer Training Video via silver70 @ 1993 Bronco, Venezuela Commercial @ If this site recovers from a little nap, sign up for free registration for some wiring diagrams (86 through 96) and Technical Service Bulletins, (80 through 96), same as by Ford @ BBB Industries- Premium Alternators, Starters, Power Steering Products | TSB's & Wiring Diagrams Al
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