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

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1983 Ford Bronco - A clean slate... Note the axles in the background - I'm literally building this truck from the ground up. 1983 Ford Bronco - It may not be obvious, but the front of the frame is resting on the ground, and the crossmember between the seat rows (2nd permanent) is su…Video 1983 Ford Bronco - I manhandled the frame onto the loose rear axle (OK, I DROPPED IT), bolted up the fronts of the springs, set the engine crossmember onto a… 1983 Ford Bronco - Under the lift, I got the rear shackles bolted up, and then picked up the front. 1983 Ford Bronco - I did a few more touch-ups on the undercoating, and started making some minor adjustments to the rear bumper. I'm gonna try to make it easi… 1983 Ford Bronco - Turns out neither weld broke in the front Lincoln-locker, but with all the damage this has caused, I'm still swapping back to an open diff. 1983 Ford Bronco - The previous hitch receiver's bolt holes don't line up with my bumper's, and these were so close that I had to fill-weld them before I coul… 1983 Ford Bronco - Back on 4 wheels! I don't expect that bottle of anti-seize on the engine crossmember to last thru the assembly process. 1983 Ford Bronco - Adjustable Camber Cam I bought a lifetime alignment from Firestone years ago, and I've gotten my money's worth. But every time they do it,… 1983 Ford Bronco - These adjustable camber cams will never have to be replaced for alignment adjustments, like the factory solid cams do. [url=http://www.supe… 1983 Ford Bronco - Tank & muffler in. Note that the muffler is a rare '96-Bronco-specific one with a 3-bolt flange, and I've homemade a mating flange to weld… 1983 Ford Bronco - I'm really getting my money's worth out of this little crane. [url=http://www.supermotors.net/registry/22771/78471-2] http://www.supermotor… 1983 Ford Bronco - I'm really getting my money's worth out of this little crane. [url=http://www.supermotors.net/registry/22771/78471-2] http://www.supermotor… 1983 Ford Bronco - Lined up... [url=http://www.supermotors.net/registry/22771/78471-2] http://www.supermotors.net/getfile/901056/thumbnail/24hoisted.jpg 1983 Ford Bronco - The dually is in Park - I'm rolling the chassis under the engine. [url=http://www.supermotors.net/registry/22771/78471-2] http://www.superm… 1983 Ford Bronco - The dually is in Park - I'm rolling the '93 chassis under the '95 engine & '85 transmission. [url=http://www.supermotors.net/registry/22771… 1983 Ford Bronco - The dually is in Park - I'm rolling the '93 chassis under the '95 engine & '85 transmission. [url=http://www.supermotors.net/registry/22771… 1983 Ford Bronco - The trans crossmember is the old '83, but I'm not sure if it's gonna work. I just haven't found the newer style yet. The 2x4 tube on the fr… 1983 Ford Bronco - It only took about a day to get the '83 from driving to this condition - I think it's gonna take a little longer going the other way... 1983 Ford Bronco - I'm reuising my old DAYSTAR Polyurethane body mounts because they're still in perfect condition. But to prevent rust & squeaks, I'm gluing… 1983 Ford Bronco - Since this '96-Bronco-only flange is so rare, it's not available from any exhaust parts supplier, or any parts store, or Ford. Neither is t… 1983 Ford Bronco - This 2x4-inch tube looks like just what I need. It easily supports the battery, and it's strong enough for an anti-wrap bar AND a skid plat… 1983 Ford Bronco - I decided to space the new crossmember down one inch to make sure it doesn't contact the cat or d'shaft, and to give a little more room bet… 1983 Ford Bronco - The battery tray came out better than I expected, but I can't really set up the anti-wrap bar until I have the truck's full weight resting… 1983 Ford Bronco - The red cable is straight out of a Land Rover; the black was a GM truck positive, but it's my auxilliary battery negative. It & the smaller… 1983 Ford Bronco - The tray is built to hold the same Gr.65 battery as the original under the hood, and it's relatively easy to unclamp & remove from below th… 1983 Ford Bronco - I added a few new circuits to the frame harness, and then laid it in. [url=http://www.supermotors.net/registry/media/930158] http://www.sup… 1983 Ford Bronco - Just checking a few things - it's coming right back off. The method I eventually used to align the body is: 1) center the body tub & core s… 1983 Ford Bronco - It's up again so I can continue working on the t-case & body mounts. 1983 Ford Bronco - The aux.batt. tray & cable are in, but I'm looking into clocking the t-case without a ring. 1983 Ford Bronco - The grounds for the 2 batteries are tied together at the block (starter), and each has extra grounds soldered to the battery clamp for high… 1983 Ford Bronco - The factory installs about 3 of these RFI straps, but I have a bunch. [url=https://www.supermotors.net/registry/media/907034] https://www.s… 1983 Ford Bronco - The inverter wire used to be the main feed from the starter relay to the underhood fuse box out of a junk '92-96 engine bay wiring harness. 1983 Ford Bronco - These Land Rover (Dunlop/Johnson) air tanks fit well where the midship fuel tank would go on a pickup, and the shortened fuel tank strap wo… 1983 Ford Bronco - I'm getting closer to bolting the body down. 1983 Ford Bronco - I decided not to build a bracket, and simply welded some studs to the tank to mount the primary compressor. I may put the second on the oth… 1983 Ford Bronco - I decided not to build a bracket, and simply welded some studs to the tank to mount the primary compressor. I may put the second on the oth… 1983 Ford Bronco - There's plenty of room around the compressor, but I'll probably route all their intakes to a single remote filter. Possibly the engine air… 1983 Ford Bronco - The OBA plumbing is coming together. The 2 open copper lines are for future compressors. Each one is isolated by a check valve. 1983 Ford Bronco - It finally occurred to me that the pressure switch wouldn't work if it was attached to one compressor, so I moved it. I also figured out ho… 1983 Ford Bronco - One of the brass quick-connectors is for the front bumper line (which I've decided to make from a common rubber air hose instead of steel),… 1983 Ford Bronco - It's tight, but there's room to work with the air fittings, or install/remove the aux.batt for fuel filter access. 1983 Ford Bronco - These junkyard hooks (just behind the axle bumpstops under the frame) have self-closing bails, so they'll retain the tiedowns if I ever tra… 1983 Ford Bronco - With a shorter bolt, the later shifter fits reasonably well on the early transmission extension. The link bar will have to be custom-made.… 1983 Ford Bronco - Like the battery, alternator, & any other high-current connections, the winch relay terminals need maintenance. I labelled each strap & wir… 1983 Ford Bronco - I found a nice '93 E4OD radiator (2-core) today in great shape. Only a couple of tiny leaks needed to be repaired. [url=https://www.supermo… 1983 Ford Bronco - 4.9L Side Cover Gasket The grommets & cork had collapsed & hardened so badly that the bolts were finger-tight. I installed the FelPro gaske… 1983 Ford Bronco - I haven't tested this JY Saginaw yet, so if it's bad, or if the previous bad one contaminated the steering box, I've added a 3/8" MagneFine… 1983 Ford Bronco - To prevent water from pooling here & causing rust, wiring corrosion, or odors, I've opened the factory drain (I still don't know why they c… 1983 Ford Bronco - Some of this is coming back out, but I wanted to see a change. The white wiring harness hooks just below the w/s are installed upside-down… 1983 Ford Bronco - This coarse screen should keep most of the leaves out of the R side, where the fresh air intake is. Cutting the edges to fit the internal c… 1983 Ford Bronco - This coarse screen should keep most of the leaves out of the R side, where the fresh air intake is. Cutting the edges to fit the internal c… 1983 Ford Bronco - This coarse screen inside the cowl (below the wiper drives) should keep most of the leaves out of the R side, where the fresh air intake is… 1983 Ford Bronco - Finer screen will keep smaller debris out of the fresh air door compartment. I'm using chunks of old magnets to hold it in place, but the s… 1983 Ford Bronco - I'm determined to keep leaves OUT of the cowl, so I lined the fresh-air openings with 1/2 x 3/4" closed-cell foam weatherstrip, and zip-tie… 1983 Ford Bronco - I think this is how most of the leaves get into the cowl (since they can't fit through the pinholes in the valance), but this foam tape sho… 1983 Ford Bronco - The last part of my leaf barrier - the seal around the antenna base where the wire comes thru the cowl. On the other side, I installed a fa… 1983 Ford Bronco - This inexpensive & common air purifier filter should remove a lot of dust & particles for a few years at least. There's enough in the box t… 1983 Ford Bronco - This HVAC vacuum reservoir was siliconed onto the evaporator cover (NOT factory), and leaking. So I removed it, wire-wheeled all the silico… 1983 Ford Bronco - Like the evaporator fins, the squirrel cage blades collect dirt, leaves, & trash. Cleaning them will keep the motor balanced, reduce noise,… 1983 Ford Bronco - Since (I THINK) everything underneath is done, the body is now bolted down. The camper is just set on to keep some of the sun & rain out. T… 1983 Ford Bronco - Not much happening during the silly season... 1983 Ford Bronco - Not much happening during the silly season, but the vise mount on the front bumper is already REALLY handy. Sound absorbers (cowl-to-fender… 1983 Ford Bronco - I finally touched up the thin paint on the doors, so I can finish building & aligning them, and then the fenders. 1983 Ford Bronco - New aftermarket replacement upper door seals (E0TZ1020518A,E9TZ-1520518-A Right; E0TZ1020519A,E9TZ-1520519-A Left) are ~$20ea plus SH, and… 1983 Ford Bronco - Other than the outer weatherbelt, upper gasket, wiring harness, & door panel, this one is finished & aligned. These VentShades are the junk… 1983 Ford Bronco - I cut the '93 E4OD t-case shifter pushrod and welded it back together shorter (too short, which is why I had to add some back). I may still… 1983 Ford Bronco - This is how the shifters will sit in 1st gear 2H. After installing the dash, I found it necessary to bend the transmission shifter back sig… 1983 Ford Bronco - Just getting the fenders out of the way temporarily. That's the '93 engine bay wiring harness piled on the engine. I haven't even started o… 1983 Ford Bronco - Just getting the fenders out of the way temporarily. That's the '93 engine bay wiring harness piled on the engine. I haven't even started o… 1983 Ford Bronco - Since the NP435 wasn't offered when the BW1356 shifter was moved to its own hole in the body, I had to make my own tunnel cover for it. I m… 1983 Ford Bronco - The door harnesses are finally done. In addition to factory PW, PL, & PM, they now also have 1-touch up/down, heated signal mirrors, puddle… 1983 Ford Bronco - Installing a '92-96 driver's door harness is hard enough with stock wiring. When there are about twice as many wires & connectors, it's a r… 1983 Ford Bronco - Other than the speaker & door panel, this door is finished. The harness is routed along the bottom of the w/s thru the white clips that als… 1983 Ford Bronco - The driver's door harness is routed along the bottom of the w/s thru the white clips that also support the firewall insualtion. ERROR: the… 1983 Ford Bronco - The driver's door harness runs inside the passenger lower A-pillar where it connects to the passenger door harness. 1983 Ford Bronco - The trailer was needed elsewhere, so I had to stick the hood on the truck. That's a new junkyard parallel-flow (R-134a) condenser that I ha… 1983 Ford Bronco - I set the t/g here 2 days ago when it started snowing, but today (74°F), I actually installed & aligned it. 1983 Ford Bronco - The modified harness installed easily & works perfectly, but I neglected to provide any mounting points for the relays & modules, so they'r… 1983 Ford Bronco - For some reason, this body doesn't have slots for all the t/g seal retainer screws. I don't remember where I stashed the retainer or seal f… 1983 Ford Bronco - The weather stayed nice all afternoon, so when the tailgate was finished, I put the taillights on, repaired this JY swingaway, and installe… 1983 Ford Bronco - In the late '80s/early '90s, the factory added 2 small holes for plastic pushpins that hold a steel plate over the original drain hole (whi… 1983 Ford Bronco - After the wiper valance was installed & aligned, I set the hood on its hinges. It may need some adjustment later... 1983 Ford Bronco - It's starting to look like a Bronco again! 1983 Ford Bronco - The wiper valance was aligned to the cowl, and the hood was aligned to the valance, and the core support was centered on the frame, but the… 1983 Ford Bronco - I cut some new fender-to-cowl shims from 1/8" hardboard and aligned the fenders to the doors, then to the core support. I had to make some… 1983 Ford Bronco - I cut some new fender-to-cowl shims from 1/8" hardboard and aligned the fenders to the doors, then to the core support. I had to make some… 1983 Ford Bronco - I just had to see what the new headlights looked like, but I can't find a grille to finish it off. I guess I threw all my old ones away. Bu… 1983 Ford Bronco - I finally found the hood latch, installed it & the cable, and tweaked the hood alignment one more time. [url=http://www.supermotors.net/reg… 1983 Ford Bronco - I finally found the hood latch, installed it & the cable, and tweaked the hood alignment one more time. [url=http://www.supermotors.net/reg… 1983 Ford Bronco - These grommets (8C167) are frequently lost, and they aren't included with replacement grilles, so I've collected some from JYs. These are n… 1983 Ford Bronco - To reduce the amount of grass, leaves, bugs, & gravel that accumulates in the condenser fins, I'm screening this new aftermarket grille. I… 1983 Ford Bronco - With this new black grille, the exterior body is practically complete. F6TZ-8200-AAA Grille argent F4TZ-8200-A Grille chrome F4TZ-8200-APTM… 1983 Ford Bronco - With this new black grille, the exterior body is practically complete. F6TZ-8200-AAA Grille argent F4TZ-8200-A Grille chrome F4TZ-8200-APTM… 1983 Ford Bronco - The HID ballasts won't be solidly mounted, but they're secure, easy to access, and high. UPDATE: Even though they're mounted well, they did… 1983 Ford Bronco - I think this foam pad was on my original '83 trans - I don't ever remember seeing one in a JY. But over the years, it has become saturated… 1983 Ford Bronco - Another example of pinnacle-level painting... 1983 Ford Bronco - Good enough for me. I'll probably rip a big gaping hole in one of them pretty soon, anyway... 1983 Ford Bronco - Good enough for me. 1983 Ford Bronco - With the clocked t-case, this skidplate is almost worthless, so I'm using its legs to mount my fabricated skidplate, which will run between… 1983 Ford Bronco - With such an elaborate metalworking facility at my disposal, folding this lip only took a few minutes. [url=http://www.supermotors.net/regi… 1983 Ford Bronco - A flat plate with the stock skidplate mounts welded on, and a couple of ribs up the middle. It underhangs the front (trans) crossmember and… 1983 Ford Bronco - There's plenty of clearance between the t-case & skidplate, even above the reinforcements. But there's a lot LESS clearance between the t-c… 1983 Ford Bronco - A flat plate with the stock skidplate mounts welded on, and a couple of ribs up the middle. It underhangs the front (trans) crossmember and… 1983 Ford Bronco - Another thing Ford should have included - a courtesy lamp switch in the tailgate jamb. I'll re-make the pad eventually so it's not an open… 1983 Ford Bronco - This was actually more expensive than it was worth, but it's an excellent test for when it matters on something else. I spent ~$60 on the d… 1983 Ford Bronco - It almost looks new! I shot a test spot on the underside, and after it dried, the only way to find it was the slight increase in gloss beca… 1983 Ford Bronco - I expected more incompatibilities, but I only had to change 2 pins to make the '93 5.8L E4OD EEC connector work with the '95 4.9L stickshif… 1983 Ford Bronco - Ugh... Lots of wiring mods in the engine bay harness, and the wires are LOOOOOOONG! 1983 Ford Bronco - The only unused fuse is K, which is also NOT on the buss bar, so I had to run the Bk/Y wire to the main stud. I'll use the R/Y to feed the… 1983 Ford Bronco - The E-fan system runs off the previously-unused Fuse K, and involves 3 relays: low speed (controlled by a dash switch & a low-temp switch),… 1983 Ford Bronco - Taped up, and ready to throw in. The relay box on the front (right) of the fuse block is for the e-fans. Their connectors & resistor are in… 1983 Ford Bronco - I started with the section across the condenser to make sure the plastic guides for the core support were spaced right, and although they'r… 1983 Ford Bronco - The large hole in the CS beside the radiator will be used for winch wiring, which is why there's split loom around its bottom edge. The wir… 1983 Ford Bronco - The yellow wire is temporary power from the aux. battery cable to the frame harness for the t/g window. 1983 Ford Bronco - The yellow wire is temporary power from the aux. battery cable to the frame harness for the t/g window. 1983 Ford Bronco - This side of the harness almost looks stock for the moment. But the extra rings & wires on the body ground (G201) are a clue that it's modi… 1983 Ford Bronco - The aux.batt. relays are under the plastic shield, which should prevent shorting on the heavy posts. The smog pump filter was moved about 1… 1983 Ford Bronco - Since I had them lying around, I added these horns in the LHR quarter panel and spliced in a Y from the horn relay output. The hose above t… 1983 Ford Bronco - This old high beam switch is now my clutch switch defeat so I can still drive on the starter if I have to. It's out of the way under the br… 1983 Ford Bronco - All taped up, and I only forgot 3 circuits! The black block near the white factory fuse block is a relay block I built from modules collect… 1983 Ford Bronco - Nothing burned when I plugged it in, so I pulled the ignition switch & started the engine. 1983 Ford Bronco - It's idling smoothly here, and I let it go a minute or 2 after the t-stat opened. The e-fan wiring, connectors, & resistor are thrown on to… 1983 Ford Bronco - THIS is how a battery should be installed: soldered clamps on clean, true terminals (positive covered) with electrical grease applied retai… 1983 Ford Bronco - These are the same fans I've been using for years (probably from an ~'07 Focus). [url=https://www.supermotors.net/registry/media/609763_1]… 1983 Ford Bronco - Hood Latch Mount Differences The deeper offset is necessary for the later parallel-flow condenser. [url=https://www.supermotors.net/registr… 1983 Ford Bronco - These help with A/C, so I'm adding them. [url=http://www.supermotors.net/registry/media/978973] http://www.supermotors.net/getfile/978973/t… 1983 Ford Bronco - Since the tube ends are identical, it only took a heat gun to bend the old tube so it would fit into the new MC. Later, I discovered that t… 1983 Ford Bronco - The clutch line is retained by a roll pin, and the nylon tube can be bent using a heat gun. 1983 Ford Bronco - The under-mirror LED cornering/off-road lights are now working, and they're MUCH brighter than they appear in this pic. They're aimed down… 1983 Ford Bronco - Christmas in May! All the big ovals are almost useless - the small one will go on my grille guard. The table that produced them is actually… 1983 Ford Bronco - This hood reel is just one of several lights I plan to add throughout the truck, but it's in the stock location for '80-86 trucks. Due to t… 1983 Ford Bronco - This plasma-cut 1/4" plate steel oval is going on the grille guard right in front of the grille ornament. So I'll really be able to... F6TZ… 1983 Ford Bronco - This 3M reflective blue tape is just big enough to fill my grille guard emblem, and I'll use the white on the letters & edge. 1983 Ford Bronco - Since rain leaks are common even when the factory sealer around the heater core nipples hasn't been disturbed, I added these foam weatherst… 1983 Ford Bronco - This was a lot nastier when I started, but it's holding pressure & it turns smoothly. Later, I found that the clutch coil is burned out. 1983 Ford Bronco - The reel light now has a hood lamp harness spliced on, and the original hood lamp harness has a 2nd connector spliced on so both lights are… 1983 Ford Bronco - I plan to have a vacuum gauge on the dash, so I needed another port on the vacuum tree, but they were all in use. So I removed the factory… 1983 Ford Bronco - The old compressor I was using temporarily (just so the belt would stay on) had a ~5" pulley, but the correct compressor's pulley is nearly… 1983 Ford Bronco - My previous fresh-air duct has seen better days, so I snagged this updated version (no accordion or front mounting tab) on a recent JY run,… 1983 Ford Bronco - Intake Screen I'd rather have the V8 fresh-air duct, but since I'm stuck with this one, I'm gonna protect it from sucking in as many bugs &… 1983 Ford Bronco - Quarter Panel Support Rods Rather than continue using the nut/bolt arrangement on the factory wheel liners (E9TZ-9928370-B), I found these… 1983 Ford Bronco - The rear rods took a little more effort to bend, but they also fit better than I expected. They started off as the same V-shaped rod that I… 1983 Ford Bronco - I took a damaged trailer connector & a good one, and made one with longer wiring. Then I finished the license & storage box wiring, but I h… 1983 Ford Bronco - To ensure any new internal grounds are thoroughly connected to the frame, body, & batteries, I changed the G400 bolt to a stud that passes… 1983 Ford Bronco - Because of all the new circuits & features I added, the floor wiring harness is now about 3x as thick under the threshhold as it used to be… 1983 Ford Bronco - There's a new connector at the base of the B-pillar for the circuits going to the rear cargo area switches. 1983 Ford Bronco - Clocking the t-case really paid off, and the skidplate is much flatter even than the NP208's was. 1983 Ford Bronco - I rebuilt the push pad for the t/g courtesy lamp switch so it's less likely to snag me or anything else. But I'll probably have to relocate… 1983 Ford Bronco - I think everything is ready for the dash to go in now... 1983 Ford Bronco - I think everything is ready for the dash to go in now... 1983 Ford Bronco - This is the dash harness just thrown onto the back of the dash. Yeah, it's a catastrophe... This is how it got like that: [url=http://www.s… 1983 Ford Bronco - The harness is now "installed" in its channel on the back of the dash, but I haven't pushed each of the takeouts through to the front. [url… 1983 Ford Bronco - After a false start last night (the inside A/C box was slightly too high), it's IN!!! I've started fishing the wires through to where they… 1983 Ford Bronco - The new relay block BARELY fits beside the clutch pedal, and I hope I don't kick it. I assumed I'd have a lot more flexibility in mounting… 1983 Ford Bronco - It makes sense to have the AutoLamp & Auto Dim controls beside the headlight switch, and it makes a LOT MORE sense to have everything mount… 1983 Ford Bronco - Working this heavy Aluminum sheet is almost like working plastic, but it'll never crack or deteriorate, and it can be grounded if necessary… 1983 Ford Bronco - This cluster required far fewer mods than the previous one, and it turns out that red wire I soldered on is useless - that location is blac… 1983 Ford Bronco - This is the majority of the new switches. They're intentionally DIFFERENT shapes, sizes, & orientations so they're NOT easily confused, eve… 1983 Ford Bronco - These chairs look nearly-new after a ride through the washing machine. [url=https://www.supermotors.net/registry/media/882905] https://www.… 1983 Ford Bronco - This is the same scrap Aluminum plate I used for the switch panels. 1983 Ford Bronco - Yeah, I know. But Ford never offered eyeball dome lamps in mocha, and this looks & works great. When the headliner is in, it should be perf… 1983 Ford Bronco - These modules have been flopping around, interfering with the glass, and catching rain. This bracket was made for them, so now they'll stay… 1983 Ford Bronco - Since this dash was designed before cell phones, and without cupholders, I added this bar between the pad & dash. I'll probably upholster i… 1983 Ford Bronco - I had been dreading adding the bung for this fan switch, but it seems my plumbing soldering might be just slightly better than I thought. T… 1983 Ford Bronco - I picked this up in a JY a few months ago just to check it out, but after feeling how hot the heater box gets just letting the truck idle a… 1983 Ford Bronco - In addition to deleting the shifter and finding the non-shifter upper column shroud, the key release button must also be added to convert a… 1983 Ford Bronco - Wiper Motor Connectors IF THE IMAGE IS TOO SMALL, click it. To make swapping wiper motors easier, splice the other connector(s) onto the or… 1983 Ford Bronco - Just a short trip to Greg's, but it's ROLLING again! The front bumper's outboard panels are only held on by tack welds, and the windshield… 1983 Ford Bronco - I used to think the push-pull cable was a mod for the original control panel, but it takes a different panel to use the dual cable, and I f… 1983 Ford Bronco - I probably could have bought new material for my old rear headliner, but it would have cost a lot more, and the color wouldn't be right. 1983 Ford Bronco - I plan to mount several indicator LEDs here. 1983 Ford Bronco - I had never seen these before, so even though one was missing, I snagged them. 1983 Ford Bronco - I can see clearly, now - the cracks are gone... The w/s installer just left. I'll put the trim back on later, after I check for leaks. [url… 1983 Ford Bronco - This was the last hurdle in bastardizing my A/C system. Most of it is '94-96 R134a parts, but that evaporator wouldn't fit in the '93 outsi… 1983 Ford Bronco - After just a few months being parked (no driving or wheeling), these were already getting tight. So I used a narrow wedge of 1/4" plate to… 1983 Ford Bronco - I haven't cleaned the leather yet, but this '02 Navigator wheel seems to be just what I needed. I thought I'd be able to use all of the non… 1983 Ford Bronco - I've never seen a Ford dimming compass temperature mirror with an AutoDimmingBrights sensor, so I made one. 1983 Ford Bronco - The heater switch looks like it belongs there. Unfortunately, a suitable panel for the passenger chair has eluded me, so its switches are a… 1983 Ford Bronco - These sockets, each of the other sockets, and the USB power adapters have [url=http://www.amazon.com/gp/product/B0087YADV2/]these switches… 1983 Ford Bronco - My power inverter is going where it will eventually be covered, so I'm adding this pigtail for a remote switch. [url=http://www.supermotors… 1983 Ford Bronco - I positioned the power inverter so it would fit in the pocket of the stock bedwall panel, or be hidden by a custom one. I'll add some exten… 1983 Ford Bronco - This passenger-assist handle took more time than I thought (because my first bracket design was wrong), but it was easier than I expected t… 1983 Ford Bronco - I chose these comfort handles (possibly from a Crown Vic, Taurus, or Explorer) because their bases are designed with standoffs to work thro… 1983 Ford Bronco - Only the wide tip of the base goes through the sheet metal - the tiny stops are barely visible that provide standoff for a headliner. I car… 1983 Ford Bronco - After drilling slightly smaller than the square, finish the hole to size & deburr it with a square file. 1983 Ford Bronco - That's "square-drilling"! 1983 Ford Bronco - When I find a headliner I like, I'll cut it out for all of these. 1983 Ford Bronco - The A-pillar handles are much stronger for climbing in; the overhead handles are just for comfort. I put the comfort handles' coathooks for… 1983 Ford Bronco - This is how I chose the handle location - the visor just clears it going into its side hook (which I added). 1983 Ford Bronco - I don't remember if Ford used that lump in the middle of the A-pillar for anything, but I'll use it for the lower bolt of the passenger-ass… 1983 Ford Bronco - To mimic the lump for the upper bolt, I started with a scrap of ~14ga steel and twisted it in a vise. Hammering on the wrench keeps the ben… 1983 Ford Bronco - To mimic the lump for the upper bolt, I started with a scrap of ~14ga steel and twisted it in a vise. Hammering on the wrench keeps the ben… 1983 Ford Bronco - Virtually identical to the lump, and easy to place where needed. Next, drill the mounting screw holes, and the handle bolt hole into the ne… 1983 Ford Bronco - With the lower bolt holding the handle in position, and the upper holding the bracket, I marked the mounting screw holes, then used a chise… 1983 Ford Bronco - My shortest 1/8" bit is a LH extractor, but it & the close-quarters drill make this much closer to being in line with where the screw needs… 1983 Ford Bronco - I temporarily mounted the bracket, ran the bolt in against the A-pillar to mark it, removed the bracket, and drilled the oversized pilot ho… 1983 Ford Bronco - Reinstall the bracket, then use a tape measure butted against the glass to measure the distance to each bolt hole. Put a small mark on the… 1983 Ford Bronco - Install the trim over the bolt holes, then use the tape to transfer the bolt hole positions onto the trim. Use a Dremel to cut out for the… 1983 Ford Bronco - They're not permanently mounted yet, but the underdash courtesy lights work well. The camera makes them look much brighter than they are. 1983 Ford Bronco - For a Bronco with an NP435 and companion flanges at both ends of the rear driveshaft: ~34.5" installed length ~29.75" collapsed length betw… 1983 Ford Bronco - The bumper & grille guard are still under construction... 1983 Ford Bronco - Some of the leftovers... 1983 Ford Bronco - This strut was left over from my trailer project, and it fits here like it was made for it. Now I gotta figure out what I got it from, and… 1983 Ford Bronco - Winch Isolator KU70039BK AVS BugFlector II 25738 (compare to Lund 18017 or 72017, and Westin 72-36708 ) Projector headlights from eBay (DOT… 1983 Ford Bronco - '98-01 Navigator Steering Wheel Wiring IF THE IMAGE IS TOO SMALL, click it. I've added the C234 pinout to this version: [url=http://www.sup… 1983 Ford Bronco - After installing a JY headliner and fitting the (unknown) comfort handles to it, I connected the AutoBright headlight sensor wiring. The ey… 1983 Ford Bronco - My engine's original rear & JY front exhaust manifolds have finally given out. They're rusted where they SHOULD seal to the head, and the r… 1983 Ford Bronco - I hadn't noticed (or maybe I just didn't want to) how badly the manifolds were leaking before I took the truck apart, so I didn't bother wo… 1983 Ford Bronco - I hadn't noticed (or maybe I just didn't want to) how bad the manifolds were leaking before I took the truck apart, so I didn't bother work… 1983 Ford Bronco - To get to this point, I removed: 1) the wheelwell, the fan & shroud, and the belt 2) the alternator & smog pump, 2ndry air pipe along the i… 1983 Ford Bronco - I forgot the front manifold is actually a JY replacement - I don't remember what year truck it came from. The Dorman manifolds are usually… 1983 Ford Bronco - The Dorman manifolds are usually supplied individually with new studs & nuts for ~$150ea, but I got a pair with no other parts from an eBay… 1983 Ford Bronco - Since my new manifolds had no accessories (just a plug in the front one & 2 in the rear one), I salvaged the original studs & EGR flare fit… 1983 Ford Bronco - After working around this shield for a while, I noticed how stupid-easy it is to R&I. 1983 Ford Bronco - Before installing the new manifolds, I sanded off as much of the soot & rust as I could from the mating surfaces. Later, I rinsed them with… 1983 Ford Bronco - Apparently, these Dorman manifolds are also compatible with the '96-only oxygen sensors. I anti-siezed the plugs & reinstalled them tightly… 1983 Ford Bronco - I moved the main block ground from the stock location on the RHF engine mount stud to the starter upper bolt, since it provides less resist… 1983 Ford Bronco - After a lot of hemming & hawing, I decided to punch a hole in the roof for the Cobra 75WXST 's antenna mount, which is a [url=https://www.a… 1983 Ford Bronco - The powdercoat on these factory '94-97 J-hook arms should last much longer than the factory paint. 1983 Ford Bronco - The weather was really nice today, so I blasted all the grime out of this carpet, loaded it with PurplePower & rinsed a few times, then lef… 1983 Ford Bronco - This is the door to a lockbox I'm installing. Yeah, it's a lot heavier than it probably needs to be, but that's me. The box itself will be… 1983 Ford Bronco - It's big, heavy, easy to use, hard to install, hard to find, and hard to break into. It's also positiviely ventilated to reduce condensatio… 1983 Ford Bronco - I picked up some tan seam sealer today (3M 08300 $31@NAPA) so no water will get in the truck or the vault. [url=https://www.supermotors.net… 1983 Ford Bronco - After it dried thoroughly, I swept up the patio and then vacuumed the carpet. Later, I flipped it, threw it on top of my patio chairs (whic… 1983 Ford Bronco - These have never worked right, so I pulled the whole mess apart and rebuilt it. Turns out the main slides were VERY sticky, the horizontal… 1983 Ford Bronco - Because of the floor mods for the power seats, the carpet has to be cut to fit the new contours, and for the new bolt locations. [url=https… 1983 Ford Bronco - Because of the floor mods for the power seats, the carpet has to be cut to fit the new contours, and for the new bolt locations. A camera d… 1983 Ford Bronco - With a few more little tweaks, the chairs fit over the carpet. [url=https://www.supermotors.net/registry/media/939627] https://www.supermot… 1983 Ford Bronco - The slot narrows at the front so the clip doesn't slip down into the chair & bend away from the slide. http://www.amazon.com/dp/B00BQ4CP3Y/ 1983 Ford Bronco - That fits well, too. After the console goes in, it'll be out-of-sight. http://www.amazon.com/dp/B00BQ4CP3Y/ 1983 Ford Bronco - RV mirror is wired up; radio & CB are working; carpet & trim are done; hands-free mic is above the mirror; phone caddy works great; so do t… 1983 Ford Bronco - I can't find a t/g threshold in the junkpile, and I need 2 more rear seat bolts, but the rest is pretty much done. I haven't decided which… 1983 Ford Bronco - There was some old spray-paint and a lot of fading, so I re-sprayed the t-case shifter bezel. 1983 Ford Bronco - The Kenwood works great, including BlueTooth. I don't use the pay apps that are built in, but it has several: Pandora, Aha, Sirius... It ha… 1983 Ford Bronco - The in-dash USB power jacks will feed these 2 cables for my phone & GPS on the dash caddy. I was barely able to reach the center defrost re… 1983 Ford Bronco - This location seemed most intuitive for the USB power, and [url=http://www.amazon.com/gp/product/B005FE44TO/]these switches fit & looked be… 1983 Ford Bronco - The cables look a little gangly from this angle, but they're not really visible from the driver's seat, so I'm happy. [url=http://www.super… 1983 Ford Bronco - I guess the old saying is true: the 3rd time's the charm. JBG finally got a rear driveshaft to me that fits. I wish they had used the later… 1983 Ford Bronco - It's nice to have REAR-wheel-drive again! 1983 Ford Bronco - To make this USELESS lid slightly more-useful, I used my paint pens to indicate the fuse ratings, & the relay purposes. I also store a few… 1983 Ford Bronco - Even with junkyard e-fans, a hodgepodge A/C system, and the evaporator inlet compression-spliced together, it works pretty well. And I have… 1983 Ford Bronco - The fuel gauge was off by ~1/4 tank, so I recalibrated it. I removed the EEC PWR and FP relays, the instrument cluster bezel & lens, the ac… 1983 Ford Bronco - I've decided to put 4 Explorer tiedowns around the cargo floor, and 2 Suburban tiedowns in the middle floor box beam. Each will have a plat… 1983 Ford Bronco - The rear ones will go in the same channel near the pinch weld & the rear box beam. 1983 Ford Bronco - These can lie flat if necessary, but they'll probably stay on top of the carpet most of the time. 1983 Ford Bronco - These should be substantially stronger, but I don't plan to haul much heavy stuff back here anyway. I positioned them so one edge is roughl… 1983 Ford Bronco - They almost look like they belong... 1983 Ford Bronco - These can all lie below the carpet, so they won't prevent me from sleeping back here (again). And even if I removed the carpet, they aren't… 1983 Ford Bronco - The original clamshell pad (E8TZ1A477A) isn't available, so I made a sleeve from a 2"-wide strip of plastic. I coiled it, stuffed it into a… 1983 Ford Bronco - When I got back from the JY with this t-case, my new t/g weatherbelts were waiting. 1983 Ford Bronco - The '92-97 non-locking glove box is very different from the locking. This one has a black box screwed to the colored front panel, with the… 1983 Ford Bronco - The '92-97 locking glove box is very different from the non-locking. This one has an interior-color box sonically welded to the front, with… 1983 Ford Bronco - It's not really secure, but it'll keep the honest people honest. 1983 Ford Bronco - Because this door panel is damaged, and because good replacements are very hard to find (new aftermarket are ridiculously expensive & made… 1983 Ford Bronco - A stealthy spot for the stealth switch. I wanted to use an illuminated switch, but I didn't have the right kind for the RKE system. I think… 1983 Ford Bronco - After an agonizingly-slow diagnosis (due to the intermittent fault), I pinpointed the PIP as the cause of the engine stalling occasionally… 1983 Ford Bronco - The PIP wraps around the shaft, so the gear has to come off. Driving out the pin is the first step. But it should be marked for correct rea… 1983 Ford Bronco - The 16-tooth bronze gear has to be pressed off the shaft, and it's TIGHT. The shaft itself appears virtually undamaged, despite having over… 1983 Ford Bronco - With the bore blocked by paper towels, I brushed the corrosion out of the bowl and off the reluctor, and clearcoated both. Then I scraped t… 1983 Ford Bronco - The PIP itself is simple to install - only getting to it is hard. Being careful of alignment, I hammered the gear back on, and drove the pi… 1983 Ford Bronco - It's ready to drop back in. Note the yellow paint mark on the lip of the bowl, which I added as this caption explains: [url=https://www.sup… 1983 Ford Bronco - Since I set it to #1TDC & marked the rotor & block (note the orange line below the PIP connector) before removal, it was easy to get it bac… 1983 Ford Bronco - With the engine idling & everything electrical running (e-fans, A/C, radio, lights), this 130A 3G puts out 92A; just above idle (around 170… 1983 Ford Bronco - After soldering the lowest joint back together, I added the hose barb at the top (lower left in the pic) that I've been doing without for s… 1983 Ford Bronco - I discovered 2 problems I didn't know I had before: 1) the t/stat cover casting has a flat spot that allows a coolant leak if the clamp isn… 1983 Ford Bronco - This new MotorCraft RS62 cap cost less delivered to my house from eBay than a Stant at Wal-Mart or a parts store, so I got 2. The old ones… 1983 Ford Bronco - Oddly, this relatively-rare switch is still in-production, but only by Pollack (probably the original supplier). [url=http://www.supermotor… 1983 Ford Bronco - Any rubber part that touches a door should be lubricated to keep it from adhering & tearing. I'm using TDL on the front doors because it wo… 1983 Ford Bronco - I found a decent velour bench in a black '92 EB Bronco, but I still have to take it apart & wash the upholstery. Most of the other junk bac… 1983 Ford Bronco - It's filthy, so it's getting stripped & washed. This almost seems like more work than the captain's chairs. [url=http://www.supermotors.net… 1983 Ford Bronco - Obviously, a lot of people have sat on the folded-down seatback, or there was a lot of heavy cargo sliding against it. But after a few well… 1983 Ford Bronco - Of course, the butt upholstery is nastier than the back. [url=http://www.supermotors.net/registry/media/894698] http://www.supermotors.net/… 1983 Ford Bronco - Even stripped, this thing is still heavy. I only put it here because I didn't have a better spot for it. [url=http://www.supermotors.net/re… 1983 Ford Bronco - Just a shot of the way it stands against the step in the floor. I always wondered if it rested on the rear footwell floor - now we all know… 1983 Ford Bronco - The dark area on the patio is the purple crap that came out of the upholstery. It was MUCH darker a second ago, and it took a while to get… 1983 Ford Bronco - I don't know what this gold goo is, but it's hardened in the fibers. Xylene did nothing, so I'm trying this now... 1983 Ford Bronco - Surprisingly, it took the gold goo out, but didn't hurt the velour at all. 1983 Ford Bronco - The seatback had a similar spot of gold paint, but it's gone now. 1983 Ford Bronco - The last things to clean are the belts, and they needed it. This was the first wash, and it almost looks like coffee. The mildew stains did… 1983 Ford Bronco - The upholstery was hanging loose at the front when I found this chair, and I've seen others the same way. So to prevent it from happening a… 1983 Ford Bronco - It looks like it belongs there! 1983 Ford Bronco - This was getting noisy, so I replaced it with a reman from O'Reilly. 1983 Ford Bronco - While swapping back to my good alternator, the bracket broke. From the color of the fracture surface, I can see that it has been cracked fo… 1983 Ford Bronco - Rather than drive the CV to the JY to look for another bracket, I'll try to weld this one back together, mainly for the practice. If it bre… 1983 Ford Bronco - I'll spare everyone pics of my booger-welds, and just skip to the (nearly) finished grinding work, which is much better than the welding wa… 1983 Ford Bronco - It's substantially thicker over the fracture than it was, but it doesn't really look it from the edge. 1983 Ford Bronco - In a couple of years, I'll probably forget I did this. 1983 Ford Bronco - Winch Remote The diagrams on the other side are what applied to mine, but IDK why they put diagrams for 4 different systems on the same pag… 1983 Ford Bronco - Curb Weight [url=http://www.supermotors.net/registry/media/1055401] http://www.supermotors.net/getfile/1055401/thumbnail/2015spring.jpg Wow… 1983 Ford Bronco - I let the front pads go a little too long, and the RHO got into the rotor, so I'm replacing them all. These all came from eBay for less tha… 1983 Ford Bronco - Removing these BJs was much faster than the previous set. The lower BJ (top in the photo) came out with one whack. The upper (using the pip… 1983 Ford Bronco - The pushrod keeps popping off the pedal lever, and I'm pretty sure it's because the bushing supplied with the MC is too soft. But it might… 1983 Ford Bronco - The clutch MC pushrod kept sliding off the lever, so I pulled the pedals ([url=https://www.amazon.com/dp/B005H7ODUE/]F3TZ-2455-A ) out to f… 1983 Ford Bronco - Even though this pedal bracket ([url=https://www.amazon.com/dp/B005H7ODUE/]F3TZ-2455-A ~$180 in 2015) is the improved design with a thicker… 1983 Ford Bronco - I assumed the shaft had worn into the bracket, but it was just this bushing. Since I don't have a replacement bushing ([url=https://www.ama… 1983 Ford Bronco - I had a piece of Teflon left over from another project, so I cut a strip and formed it into a ring using a hose clamp & a heat gun. SEE THE… 1983 Ford Bronco - After cutting the ring to the right circumference, I installed it. Fortunately, it's too thick, so I had to use a stack of washers & the nu… 1983 Ford Bronco - Technically, a new lever [url=https://www.amazon.com/dp/B0042HE68Y/]E7TZ-7A554-A is required every time, and they're only ~$25, but I'm goi… 1983 Ford Bronco - I could tell an immediate difference in the clutch pedal feel, and it seems to work better, too. [url=http://www.supermotors.net/registry/m… 1983 Ford Bronco - I bent the old drag link pushing down trees on my new property, and the RHO end was really worn when I did the ball joints last week, so I… 1983 Ford Bronco - 2-Color LED & Resistor for 12V use These are for my dual-battery system. The LED's color will tell me which battery is weak. [url=https://w… 1983 Ford Bronco - I decided this new bumper lid had developed enough "patina", so I sanded the rust layer off & then rattle-canned it. 1983 Ford Bronco - This was new less than 8 months ago, and I can't believe a 6-cyl & 4-speed pushing 32" A/Ts on pavement & wet dirt could break a DECENT dri… 1983 Ford Bronco - This was new less than 8 months ago, and I can't believe a 6-cyl & 4-speed pushing 32" A/Ts on pavement & wet dirt could break a DECENT dri… 1983 Ford Bronco - This is buildup from me widening the roads during the ice storm... 1983 Ford Bronco - This turned out to be slimier than it looked; especially on the 2nd pass. I slid to the trees, then winched forward about 20'. 1983 Ford Bronco - After a year of driving, light wheeling, and knocking down trees on my property, it still looks pretty good underneath. [url=http://www.sup… 1983 Ford Bronco - After a year of driving, light wheeling, and knocking down trees on my property, it still looks pretty good underneath. [url=https://www.ru… 1983 Ford Bronco - After a year of driving, light wheeling, and knocking down trees on my property, it still looks pretty good underneath. [url=https://www.ru… 1983 Ford Bronco - After a year of driving, light wheeling, and knocking down trees on my property, it still looks pretty good underneath. [url=https://www.ru… 1983 Ford Bronco - As tight as the Aux.Bat. is, R&I is very easy. It's coming out now so I can swap the t-case. [url=https://www.supermotors.net/registry/medi… 1983 Ford Bronco - The t-case started slipping over the course of 2 days of light driving. I have a spare to put in while I see how bad this one is, but the w… 1983 Ford Bronco - Despite the aux.bat. on the extra crossmember, it's still pretty quick & easy (when it's not raining) to drop the t-case. 1983 Ford Bronco - It's springtime, and there's a hot little Mustang that keeps passing by... 1983 Ford Bronco - The popping/clashing wasn't the old JY auto hub locks, and it wasn't the t-case I ran dry. I don't know how I did this, and to only 3 of th… 1983 Ford Bronco - On close inspection, I decided that the tooth in the foreground (bottom of the pic) broke off first, and that caused all the other damage.… 1983 Ford Bronco - This is what settled out while I was swapping the diff. gears. It's also why I'm using this disposable makeshift drain pan - I didn't want… 1983 Ford Bronco - Rather than dump more money into new gear oil for this old axle, I just filtered what came out and put it back in. It's probably as clean n… 1983 Ford Bronco - The benefits of having a big junkpile... 1983 Ford Bronco - Spring is here. 1983 Ford Bronco - It took over a year, but I found a replacement fender. As before, the first step was to pressure wash it a few times. Then I removed all th… 1983 Ford Bronco - I painted it white inside, just like before. [url=http://www.supermotors.net/registry/media/1057283] http://www.supermotors.net/getfile/105… 1983 Ford Bronco - After a light sanding & another wash or 2, I smeared black paint all over the outside. Just LOOK at that perfect orange-peel! [url=http://w… 1983 Ford Bronco - My beautiful orange-peel finish almost settled out overnight. But the local insect population was making the hard sacrifices to try to reta… 1983 Ford Bronco - The one right above the wheel arch appears to have been the strongest, judging by the length of his trail. All the other LOSERS appear to h… 1983 Ford Bronco - It's a high-protein paint job. [url=http://www.supermotors.net/registry/media/1057285] http://www.supermotors.net/getfile/1057285/thumbnail… 1983 Ford Bronco - A bird was not impressed with my work yesterday, so I sanded his commentary off & washed it again. [url=http://www.supermotors.net/registry… 1983 Ford Bronco - Since the '93EB body tub is still on my 2-post lift, I can't paint this whole hood at once like last time. [url=http://www.supermotors.net/… 1983 Ford Bronco - I'm getting REALLY good at this orange-peel finish, but there's a BIG mismatch in the quantity of bugs embedded in this paint, compared to… 1983 Ford Bronco - Good weather today, so I'm swapping body parts. 1983 Ford Bronco - All the damage is gone now, but I'm gonna pull that wheelwell and maybe the Y-pipe to fix the exhaust leak. 1983 Ford Bronco - Out with the bad... 1983 Ford Bronco - The way I installed my hood struts is causing the hood to drift forward, so I'm adding a bolt to each lower hinge plate to pull it back int… 1983 Ford Bronco - The tan paint is still wet, but it looks right. 1983 Ford Bronco - Ready to tear up again! ...well, after I decide what to do with the new headlights: install them untouched like the first set, or tint them… 1983 Ford Bronco - These guys seemed to be really impressed with my work - they were all clapping. 1983 Ford Bronco - These guys seemed to be really impressed with my work - they were all clapping. 1983 Ford Bronco - Since the aux.batt. and crossmember were down anyway from the clutch job, I finished the anti-wrap bar design, and most of the fabrication.… 1983 Ford Bronco - After a year of procrastinating & screwing around, I decided to finish the anti-wrap bar today. Unlike typical "traction bars" which limit…