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Rear Disc Conversion

From 1983 Ford Bronco “That dirty old truck” — documented by Steve83.

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1983 Ford Bronco - My disc axle donor is a 2006 E150. 2004-13 E150s use the same 5-on-5.5" lug pattern as all Broncos & most pre-'97 F150s, which is why… 1983 Ford Bronco - My disc axle donor. The axle tag is: V750R 3 55 88 5K17 1983 Ford Bronco - My '06 E150 disc axle cost ~$180. I had to make another load for the 16" steel rims (with worthless tires, which I returned that day).… 1983 Ford Bronco - They're very similar, but the spring perches & shock mounts are in the wrong positions for a Bronco. And the van pinion is farther to the p… 1983 Ford Bronco - The new shock brackets are [url=https://www.amazon.com/gp/product/B01IRYPDFM]Rusty's Universals , but I had to re-cut them to match the ang… 1983 Ford Bronco - I made the rough & 2nd cuts with a thin 5" wheel ( Metabo 655334000 ) to remove the spring perches & shock brackets. 1983 Ford Bronco - Grinding the tube down smooth is probably the hardest step in this process. 1983 Ford Bronco - Including the Bronco-specific 7-degree shims, the spring angle is about 19 degrees from the pinion (using an iGaging AngleCube Digital Leve… 1983 Ford Bronco - These squares work perfectly as a big caliper to get accurate measurements across the diff housing. The spring centers are 44 3/8 inches (s… 1983 Ford Bronco - I leveled the tube & pinion on my vise table (using an iGaging AngleCube Digital Level or newer cheaper version ) and laid out the position… 1983 Ford Bronco - Setting these angles (using an iGaging AngleCube Digital Level or newer cheaper version ) & tacking them went quickly, and my welds look be… 1983 Ford Bronco - After sandblasting & painting the rotors, I turned them at a friend's shop. They were very slightly warped, and the drums were barely taper… 1983 Ford Bronco - I painted the rotors (before cutting) with black (instead of the original silver) BBQ paint. The axle tubes had undercoating before, and no… 1983 Ford Bronco - I drilled the new shock mount for the original e-brake cable guide's bolt, and the brake line guide's bolt, so everything is routed & retai… 1983 Ford Bronco - I drilled the new shock mount for the original e-brake cable guide\\'s bolt, and the brake line guide\\'s bolt, so everything is routed & r… 1983 Ford Bronco - A lot has changed, and a lot of money has been spent, but not on anything that shows... To put this in my '83 Bronco, I had to regear it. I… 1983 Ford Bronco - These factory wheels are apparently made by AccuRide. [url=https://www.supermotors.net/registry/media/266155] https://www.supermotors.net/g… 1983 Ford Bronco - While the E6000 was curing on the disc axle's cover, I got the tires (Cooper AT3s) swapped to the 2006 van rims. Yeah, I know they're not s… 1983 Ford Bronco - Not a moment too soon... Not only is this shoe disintegrating; the autoadjuster cable is caught between it & the backing plate. No wonder t… 1983 Ford Bronco - I expected this to take a while, but it's only been about 1.5 hrs since I drove the truck here. And part of that was taking pictures. 1983 Ford Bronco - The U-bolts needed washing (I'm reusing them temporarily to find out what length to buy), but while they're drying, I'll put everything els… 1983 Ford Bronco - The leaf spring & sway bar U-bolts were the last things to go on. The driveshaft angle looks good, but I haven't measured it yet. I reverse… 1983 Ford Bronco - I found that the E150 e-brake cables connected directly to the Bronco pedal cable. But it's about 5" too long to lock into the Bronco… 1983 Ford Bronco - This was pretty obvious, and elegantly simple, while still being overbuilt, and easy-to-clean. I haven't tested it yet, though... 1983 Ford Bronco - The van's Left cable goes straight under the frame (like the original Left cable did) through the frame tab, to the van's Right cable sheat… 1983 Ford Bronco - The e-brake cables are drooping because I haven't yet installed their original hanger springs from the van. [url=https://www.supermotors.ne… 1983 Ford Bronco - The van hose (F2UZ-2282-A) fit the Bronco frame & brake line. [url=https://www.supermotors.net/registry/media/266155] https://www.supermoto…