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66-96 Ford Broncos - Early & Full Size
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lascassas_camper

Tool to remove top

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What tool (size) do i need to remove the bolts from my 1994 Ford Bronco? The tops never been off and when I removed the trim, there is some kind of allen head bolt. I tried drilling out the center of an allen head wrench, but it just wasn't the right size. Where can I get the correct tool? valleyview7083@yahoo.com

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You can get a torx head socket at any Autozone, Napa, WalMart, etc. You can also get them as screwdrivers but you'll want the sockets instead. I haven't yet had one of the Bronco's new enough to use the torx heads so I can't give you a size but they're probably T15, T20 or T25. The auto parts place should let you run out & fit it to see which you'll need.

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On your 94 Bronco, the removeable top bolts are a security Torx, with a little dimple in the center. Your best bet is to drive to the local auto parts store, and get the se that fits. This will save you 3 or 4 trips back and forth for the right one. The rear seat belts attach to the hardtop, so they are non-functional when you remove it. You can retro-fit some older style lap belts for the rear bench., JSM84

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I got a set of security torx bits from auto zone spec for my 95 and there fairly cheap $ and it only takes about 5 min to unbolt all and it s a good idea to have a hoist systemor some friends to help take the top off its not to heavy but bulky

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Its off! It only took me about 2 1/2 hours, 3 of the #40 Torx drivers and 1/2 a can of wd40, and a bath....but i got it off. It sure was filthy under the interior trim....15 years of dust and grime.

:rolleyes:

The PO said the top had never been off except for a factory re-paint and I beleive it. I'm going to buy some different bolts to secure the top, those torx heads are too easy to strip out the nut driver and my patience.

 

***I was looking at the rear seat belt situation (and since the shoulder bolt was bolted in the fiberglass/plastic top anyway) I beleive after a little measuring and with a piece of 1/4 flat steel behind the inner sheetmetal, I believe I can bolt the top of the shoulder belt to the inner side of the bed cap and have it still be functional and safe.

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I suppose you *could* add a reinforcing plate and run it that way but like JSM84 mentioned, a seat from an earlier truck will have the lap belts integrated into it and is an inexpensive bolt-in. The junkyard I usually go to has several at the moment & he wants $50 for one. Not a bad price really. Do a little looking & you can probably find one to match your interior or toss a $12 Wal-Mart seat cover on it.

 

Yeah, twisting up those large Torx sockets get old fast. I'm rewiring & doing a lot of body work on a friends CJ7 & wasted a pair of large T50's trying to get the rusted rollbar bolts out. Finally wound up getting a hardened black-oxide set for impact-wrenches. They work much better & it's nice to be able to use the impact instead of a ratchet.

Edited by Broncobill78

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I use a t-40 in my dewalt 18v impact makes short work of them. I seem to lose the little clips the bolts thread into. I got a buddy with a 91 xlt, his back belts bolt just above the rear wheel well. next time im at the junk yard im going to look for a set.

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...I believe I can bolt the top of the shoulder belt to the inner side of the bed cap and have it still be functional and safe.
No, neither functional nor safe. The '92-96 rear shoulder belt is too long to lower the top point more than an inch or 2 - there's not enough room on the reel to store the unused belt, so it would never tighten on the occupant. And it's not safe because a belt running downward from the shoulder creates a compressive force on the chest cavity/spine during a collision, which would break the collar bone & possibly the spine/ribs. It must run at the designed angle to be safe. If you want to modify it, modify it ONLY using a total factory (DOT-approved; insurance-accepted) seat belt system by swapping in a '78-91 rear seat with attached belts.
I got a buddy with a 91 xlt, his back belts bolt just above the rear wheel well.
Those aren't his original belts because '91 didn't have rear shoulder belts, and again - it's NOT safe.

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