Philofab's 1993 Bronco AKA "Lucky Bronco #3"

[philofab]

Anyone interested in my 4wd Bronco build up over here? It's still getting more done to it every day....






It started out as a budget build and quickly escalated. I use it at off road racing events for retrieval, track maintenance, prerunning, marking courses, ect.

[eshallbetter]

Post up the rear axle stuff!

[philofab]

Originally Posted by eshallbetter

Post up the rear axle stuff!

Full on lurker over here huh?

This Bronco originally came with an 8.8. Truck had about 135K miles on it and that rear end died in short order after the larger tires. Pinion went away and destroyed the R&P. Rather than build another or repair it, I built a 9".



This is the 9" I bought from a JY.




Truss I got from Giant Motorsports





Truss after welding..




Truss welded to housing.




Alignment after welding.




4.56 Detroit 3rd I got from a early Bronco shop in Yucca. Can't remember the name.




Currie axle retainers.




Bung installed for ring gear inspection and filling.

[philofab]

VSS and brake lines.





Installed.

[philofab]

The 9" did well for a while but the manual transmission, 35 & 37" Toyos took their toll on the wheel bearings and ring and pinion. I want to go wider than stock now too so it's time for a new axle.

Plans now include a hybrid Sterling / D60.

10.25 Sterling center section. (Already has VSS for speedo)
D60 front spindles bolted to Ruff Stuff Specialties mounts.
Yukon R&P
Yukon Grizzly Locker
Yukon Dana 60 5x5.5 Hubs
5/8-18 Studs
Stage 8 Locks
Yukon 35 Spline drive plates
Yukon Hybrid 35 spline axles (Ford 35 spline on inside, Dana 60 35 spline on outside)
Baer Brakes of some sort with 12" rotors.
Parking brake moved to t-case.

[philofab]

Some of the stuff has come in for the new axle build.

[broncdawg]

Lookin' good as usual! Sick in bed, so nuthin' to do but lurk!

[afecko]

If you don't mind, what were your specific problems with the 9"?

[philofab]

Originally Posted by afecko

If you don't mind, what were your specific problems with the 9"?

The ring and pinion only last about a year, and I've gone through 3 or 4 sets of the wheel bearings. At first I was bending the backing plates but that stopped once I went to the Currie retainers. The bearings just can't handle the 127# wheels and tires.

I broke the case once but no problems since upgrading to a Yukon nodular third.

[Brutpwr]

Looks good!

[BigBlue&Goldie]

Any more shots of your front bumper?

I'm looking to build one, but I don't have a damn bender!

[DREWZILLA]

Nice ,I race in class 3.Lookin awesome.classracing.com

[philofab]

Originally Posted by BigBlue&Goldie

Any more shots of your front bumper?

I'll get some more pics of it. It's coming off to get sold at the Leduc swap meet. Building something new!

Originally Posted by DREWZILLA

Nice ,I race in class 3.Lookin awesome.classracing.com

I'm on class3racing. I'm just a bit of a lurker over there.

[JPI Motorsports]

Very cool bro. I have an 89 Bronco I've been wanting turn into a street/prerunner type rig.
Good luck with the build.

[philofab]

Front bumper pics:

[philofab]

Got some engine mounts from my friend Shawn Heck for the Bronco. These are JBG units.

[philofab]

[shawn t]

"10.25 Sterling center section. (Already has VSS for speedo)"

Is that the main reason for the Sterling vs. maybe a D70?

[philofab]

Originally Posted by shawn t

Is that the main reason for the Sterling vs. maybe a D70?

The D70 came with a VSS in dually Ford truck rear ends but those cost more from the JY and are harder to find.

[DB_1]

There's a few threads on dezertrangers where some guys had tone rings cut out and mounted on the driveshaft with a bracket mounted on the t-case to hold the sensor. Just search VSS and it should bring up those threads.

[philofab]

Originally Posted by DB_1

There's a few threads on dezertrangers where some guys had tone rings cut out and mounted on the driveshaft with a bracket mounted on the t-case to hold the sensor. Just search VSS and it should bring up those threads.

I'm aware of all those. Southwest Performance, Leduc Prefun, and Brea Auto Electric all make kits.

My current 9" has a VSS in it too.

[philofab]

Did a little more work on my coil over mounts today. I need to get a raised lower spring retainer as the flat one hits the beam on droop.




Got a new radio to install once I find room for it from TCM_GLX.




I also found out why the passenger seat is loose. Broken stud. For some reason everything keeps coming loose and cracking on the Bronco. Odd.

[philofab]

I limited my up travel a little bit and also started trimming the box.




As you can see the negative camber is excessive on the passenger side and will shorten the life of the knuckles and bearings if it went farther. Limiting the bump also will give more room for the steering as it hits the frame before the beam does.

[philofab]

Passenger side is almost done. I need to get some tear drop gussets cut like the one shown and add a little piece of 1"x.250 DOM to the upper shock mount so I can run a longer bolt/shank and reinforce it a little bit. Maybe weld it up too....

[philofab]

Finally started the other side. Still need to do the lower mounts, the support bar to the cross member, and cross bar to the other side, and redo all the brake lines.

The brake lines should be fun. Getting rid of that worthless ABS pump is a lot of work... most of the lines have to be replaced. Going to go to -3 AN lines and run them up the radius arm. Should end up with 4 identical -3 braided lines and hard lines everywhere else. Then I can carry one -3 line and one -3 cap as a backup.