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4bt Cummins Swap

From 1996 Ford Bronco “Big Red”, documented by Impact.

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1996 Ford Bronco - 20190727 - Got back with the 4bt CPL#1839 HX30W P7100 from a seller on Craigslist 1996 Ford Bronco - 20190727 - Got back with the 4bt CPL#1839 HX30W P7100 from a seller on Craigslist 1996 Ford Bronco - 20190729 - Barely fit the trailer in the garage. Time to shuffle things around and clean up this disaster of a man cave.â%uFFFD%uFFFD 1996 Ford Bronco - 20190731 - Rented an engine lift and had just enough clearance. Turns out trying to get it lifted and maneuvered alone was a chore. Didn't… 1996 Ford Bronco - 20190801 - I get the chain adjusted, shift the weight of the engine more toward the right leg, and voila! Finally get the dang thing off an… 1996 Ford Bronco - 20190801 - I get the chain adjusted, shift the weight of the engine more toward the right leg, and voila! Finally get the dang thing off an… 1996 Ford Bronco - 20190926 - After the shop graciously lets me borrow their known-good lift and I recruit a long-time friend and his truck, the engine (and t… 1996 Ford Bronco - 20191011 - Dropped it off at the shop 1996 Ford Bronco - 20191015 - Aluminum fuel tank skid plate is in from Desolate Motorsports 1996 Ford Bronco - 20191015 - Gauge pod and gauges in from GlowShift 1996 Ford Bronco - 20191016 - Plastic fuel tank from Bronco Graveyard, confirmed with the manufacturer it's good for diesel 1996 Ford Bronco - 20191011 - Lift pump on the 4bt, shouldn't have to buy one. 1996 Ford Bronco - 20191021 - Most of the new parts are on the table, all the old stuff pulled out is on the ground in front of and to the right of the table.… 1996 Ford Bronco - 20191022 - The old and (probably) tired 351w (~250k miles).​ 1996 Ford Bronco - 20191022 - The old and (probably) tired 351w (~250k miles).​ 1996 Ford Bronco - 20191017 - Engine mounts are in from Diesel Conversion Specialists. Very heavy. 1996 Ford Bronco - 20191021 - UPS was nice enough to ignore my note to put it in the driveway and I was surprised to find it blockading my egress. New 96-97 P… 1996 Ford Bronco - 20191023 - Engine, transmission, driveshaft, exhaust, fuel tank and lines, and radiator all stripped out. 1996 Ford Bronco - 20191023 - 4bt is apart and ready for cleaning, paint, and upgrades. 1996 Ford Bronco - 20191023 - Inside of the timing cover is stamped "Made In U.S.A". 1996 Ford Bronco - 20191028 - Not every day I get to see the Bronco this barren, especially underneath. A lot cleaner than I expected as far as rust goes. The… 1996 Ford Bronco - 20191028 - Not every day I get to see the Bronco this barren, especially underneath. A lot cleaner than I expected as far as rust goes. The… 1996 Ford Bronco - 20191028 - Fuel tank cross members are rusty, but some stabbing around it showed it's surface. A wire wheel and POR15 will fix that up sinc… 1996 Ford Bronco - 20191028 - Fuel tank cross members and hitch assembly are all rusty, but some stabbing around it showed it's surface. A wire wheel and POR1… 1996 Ford Bronco - 20191028 - ARP head studs documentation. Pretty confused because instructions say to mill the pedestals, but they look like they are flat a… 1996 Ford Bronco - 20191028 - Pedestels seem milled and flat already. Or maybe a step needs to be milled into it for the ARP head studs. Definitely not bolt i… 1996 Ford Bronco - 20191031 - Got my Dodge A/C manifold in from Diesel Conversion Specialists, just needs to be crimped to the ford lines. 1996 Ford Bronco - 20191101 - Machined rocker pedestals in from Power Driven Diesel so the ARP head studs can be installed. 1996 Ford Bronco - 20191104 - 4bt block getting painted. This is after the first coat. One or so more to go. 1996 Ford Bronco - 20191104 - 4bt block getting painted. This is after the first coat. One or so more to go. 1996 Ford Bronco - 20191105 - Oil pan painted and drying. 1996 Ford Bronco - 20191105 - Valve covers painted and drying. 1996 Ford Bronco - 20191105 - Exhaust manifold painted and drying. 1996 Ford Bronco - 20191105 - More parts painted and drying. 1996 Ford Bronco - 20191105 - Head painted and drying. Ran out of paint, it needs another coat or two. 1996 Ford Bronco - 20191105 - Head painted and drying. Ran out of paint, it needs another coat or two. 1996 Ford Bronco - 20191105 - Timing cover painted and drying. 1996 Ford Bronco - 20191105 - Timing cover painted and drying. 1996 Ford Bronco - 20191105 - Block painted and drying. Ran out of paint, it needs another coat or two. This little plug looks like it might already be a bloc… 1996 Ford Bronco - 20191105 - Block painted and drying. Ran out of paint, it needs another coat or two. This little plug looks like it might already be a bloc… 1996 Ford Bronco - 20191106 - New chrome grill is in. The chrome on the old one is bubbling and peeling. May as well get one of these while everything is apar… 1996 Ford Bronco - 20191106 - New chrome headlight bezels are in. The chrome on the old ones is bubbling and peeling. May as well get these while everything i… 1996 Ford Bronco - 20191106 - Transmission is apart and all new steel 4r100 parts are in including a powerstroke torque converter. 1996 Ford Bronco - 20191107 - Second coat of paint, finished, and ready to get put back together. 1996 Ford Bronco - 20191107 - Second coat of paint, finished, and ready to get put back together. 1996 Ford Bronco - 20191107 - Second coat of paint, finished, and ready to get put back together. 1996 Ford Bronco - 20191107 - Second coat of paint, finished, and ready to get put back together. 1996 Ford Bronco - 20191112 - Engine is being put back together. Looks pretty good for a rattle can paint job I think. 1996 Ford Bronco - 20191112 - Engine is being put back together. Looks pretty good for a rattle can paint job I think. 1996 Ford Bronco - 20191114 - Transmission pan came in. Mag Hytec, offers a bit deeper of a pan, better cooling, more fluid, and a port for a temp sensor. 1996 Ford Bronco - 20191114 - Installed one 3k governer spring successfully in the p7100 pump. Spindle is straight. Turn it over and do the other one. 1996 Ford Bronco - 20191114 - Installed the second one, turned over gently to make sure movement is good. Slight catch in the motion. Back it off, look at the… 1996 Ford Bronco - 20191114 - Installed the second one, turned over gently to make sure movement is good. Slight catch in the motion. Back it off, look at the… 1996 Ford Bronco - 20191115 - Engine still coming together. High mount AC brackets are installed with the 45 degree lower water neck. This is needed to work w… 1996 Ford Bronco - 20191115 - Vertical upper water neck is a must to retain AC and use the DCS High mount AC kit. 1996 Ford Bronco - 20191115 - Pacbrake universal remote oil filter mount kit is the blue puck here. 1996 Ford Bronco - 20191118 - New fan/idle bearing, M10 1.5thread pitch by 140 mm long bolt as there was one missing for the lower water neck, and 8 rib pulle… 1996 Ford Bronco - 20191118 - Fan/idler pulley is a bit stiff in turning, so got a new bearing from NAPA Part#BRG BD35 1996 Ford Bronco - 20191118 - Documentation on the high mount AC kit specifies a new 8 rib pulley for the alternator (Part#f65z10344aa, Motorcraft GP720). 1996 Ford Bronco - 20191202 - Fuel pump is cleaned up, gaskets replaced, flyweights replaced, governor spring kit installed, upgraded fuel delivery valves ins… 1996 Ford Bronco - 20191202 - Turbo was sandblasted, painted, center cartridge replaced, and new gaskets. 1996 Ford Bronco - 20191202 - Turbo was sandblasted, painted, center cartridge replaced, and new gaskets. 1996 Ford Bronco - 20191204 - Engine is together. Just needs installed and all plumbing. 1996 Ford Bronco - 20191204 - Engine is together. Just needs installed and all plumbing. 1996 Ford Bronco - 20191204 - Engine is together. Just needs installed and all plumbing. 1996 Ford Bronco - 20191204 - Engine is together. Just needs installed and all plumbing. 1996 Ford Bronco - 20191204 - Engine is together. Just needs installed and all plumbing. 1996 Ford Bronco - 20191204 - Before & after comparison 1996 Ford Bronco - 20191219 - Engine and transmission are in the Bronco now and everything fit together great so far! 1996 Ford Bronco - 20191219 - Pretty tight fit between the engine and crossmember 1996 Ford Bronco - 20191219 - Pretty tight fit between the engine and crossmember 1996 Ford Bronco - 20191219 - Pretty tight fit between the AC and alternator and the passenger side, but it fit very well. 1996 Ford Bronco - 20191219 - This plate is for the tachometer sensor which is directly above this wheel at the top. Some grinding was necessary to get that b… 1996 Ford Bronco - 20191219 - The adapter kit from DCS made installing the engine, fitting the transmission to the engine in its original mounting location, a… 1996 Ford Bronco - 20191219 - Everything fit well, even with the rear/bottom dump exhaust manifold... except the outlet is 3 inches and there isn't 3 inches o… 1996 Ford Bronco - 20191219 - Everything fit well, even with the rear/bottom dump exhaust manifold... except the outlet is 3 inches and there isn't 3 inches o… 1996 Ford Bronco - 20191223 - Tried flipping the existing manifold but the high mount AC bracket and the mounting bracket for lifting the engine are in the wa… 1996 Ford Bronco - 20191226 - Here is a view of the 7.3l diesel radiator trying to fit in a Bronco core support. As you can see... it doesn't fit. The diesel… 1996 Ford Bronco - 20191226 - Here is a view of the 7.3l F250/F350 core support. The diesel F250 and F350 core supports are the same, and are deeper than the… 1996 Ford Bronco - 20191226 - Here is the size difference between the V8 gas radiator and the 7.3l diesel radiator. I got the Mishimoto OEM aluminum replaceme… 1996 Ford Bronco - 20191226 - Because the new core support is so much deeper, I think I'm going to have an issue with this sway bar being in the way. Will lik… 1996 Ford Bronco - 20200102 - Core support is painted and installed. Fits up nicely, but does get in the way of the sway bar. 1996 Ford Bronco - 20200102 - Received and installed the center dump exhaust manifold. Bolting it up to bottom dump wouldn't clear the high mount AC kit. Bolt… 1996 Ford Bronco - 20200107 - Interwebs failed to yield some 7.3l radiator brackets to mount the radiator to the core support. So I went junkyard diving and $… 1996 Ford Bronco - 20200110 - "New" style Throttle Position Sensor bracket and sensor. 1996 Ford Bronco - The DieselConversionSpecialists TPS P7100 Guide points out what I think are the typical TPS bracket assemblies, but don't seem to match min… 1996 Ford Bronco - 20200114 - Turns out I may have a TPS bracket assembly that is different than most 4bt/6bt setups out there. The bracket and sensor I got w… 1996 Ford Bronco - 20200113 - Custom dual fan setup from FF Dynamics. Should bolt up like OEM to the 7.3l support and radiator. The second one is identical to… 1996 Ford Bronco - 20200113 - Fan controller, sensor, and wiring harness assembly for the FF Dynamics custom fan. 1996 Ford Bronco - 20200114 - Another glamour shot of the front end on the ground. Everything seems to fit nicely. 1996 Ford Bronco - 20200115 - I decided I wanted stainless steel piping for the exhaust and needed to get an HX30w internal wastegate Downpipe Turbo Flange V-… 1996 Ford Bronco - 20200115 - Downpipe has been started 1996 Ford Bronco - 20200115 - Gauges are getting ready to go in. Oil pressure, trans temp, EGT, and boost. 1996 Ford Bronco - 20200115 - Gauges are about to go in. GlowShift didn't have a medium mocha 4 gauge pod. It came in black, so painted it up to hopefully mat… 1996 Ford Bronco - Cummins Part# 4089112 12 valve throttle linkage for the 6bt w/ P7100 1996 Ford Bronco - 20200227 - AFC Live unit mounted under the power point. It's recessed back a bit more since I hang a phone charger here pretty much constan… 1996 Ford Bronco - 20200227 - Lines leading from the AFC Live tuner to the AFC on the engine. 1996 Ford Bronco - 20200227 - The adjustable screw to adjust PSI for the turbo. 1996 Ford Bronco - 20200304 - Power steering reservoir is mounted. 1996 Ford Bronco - 20200302 - Intercooler is mounted. 1996 Ford Bronco - 20200302 - Intercooler is mounted. 1996 Ford Bronco - 20200320 - FF Dynamics custom fan setup installed, fits up perfectly. 1996 Ford Bronco - 20200320 - FF Dynamics custom fan setup installed, fits up perfectly. Leaves plenty of space between the engine and fans as well. 1996 Ford Bronco - 20200320 - FF Dynamics fan relay and controller mounted on the passenger fender well behind the battery. 1996 Ford Bronco - 20200320 - FF Dynamics Fan is mounted with clips that push through the radiator fins and are secured on the opposite side of the radiator. 1996 Ford Bronco - 20200320 - Power steering lines are plumbed in and completed. Auxiliary port is capped as shown at the top of the photo. 1996 Ford Bronco - 20200320 - Power steering lines have been run. 1996 Ford Bronco - 20200327 - Titanium charge pipes are being welded up. 1996 Ford Bronco - 20200327 - Titanium charge pipes are being welded up. 1996 Ford Bronco - 20200327 - Titanium charge pipes are being welded up. 1996 Ford Bronco - 20200327 - Testing fit of the first leg of the titanium charge pipes. 1996 Ford Bronco - 20200401 - Gauges are wired up and operable as far as we are able to test without being able to start the engine yet. Gauges even dim when… 1996 Ford Bronco - 20200403 - Transmission controller is going in. Confirmed wiring to enable the overdrive toggle on the shift lever. Everything should be go… 1996 Ford Bronco - 20200403 - All of the wiring is being cleaned up nicely, routed, and attached in appropriate places to secure them. The shop is doing a gre… 1996 Ford Bronco - 20200403 - One of two charge pipes (not including any intake piping) is finished. 1996 Ford Bronco - 20200403 - One of two charge pipes (not including any intake piping) is finished. 1996 Ford Bronco - 20200403 - One of two charge pipes (not including any intake piping) is finished. Rigid 90 degree hose here to mate it to the intercooler. 1996 Ford Bronco - 20200403 - Better shot of the transmission fluid lines running to the auxiliary cooling built into the radiator. 1996 Ford Bronco - 20200403 - subframe supporting the headlights and grill is on. Clears the intercooler with minimal trimming. 1996 Ford Bronco - 20200403 - subframe supporting the headlights and grill is on. Clears the intercooler with minimal trimming. 1996 Ford Bronco - 20200403 - This is the piece needing trimmed off to clear the intercooler. It resides on the backside of this intersection on the subframe,… 1996 Ford Bronco - 20200403 - Because the diesel core support is deeper to fit the larger radiator, the hood latch support beam was too short and needed to be… 1996 Ford Bronco - 20200403 - Because the diesel core support is deeper to fit the larger radiator, the hood latch support beam was too short and needed to be… 1996 Ford Bronco - 20200403 - This is the original AC pressure switch which is going to be retained and relocated along the AC lines elsewhere. 1996 Ford Bronco - 20200410 - Charge pipes are done 1996 Ford Bronco - 20200410 - Charge pipes are done 1996 Ford Bronco - 20200410 - Charge pipes are done 1996 Ford Bronco - 20200410 - Fuel Shutoff Solenoid wired up with an 80amp relay. 1996 Ford Bronco - 20200410 - Fuel Shutoff Solenoid wired up with an 80amp relay. Relay is located here on the passenger side. 1996 Ford Bronco - 20200410 - TPS setup arrived. 1996 Ford Bronco - 20200421 - Put 7 gallons of diesel in her. The diesel fuel neck fit right up with no modifications. 1996 Ford Bronco - 20200427 - Boost sensor is welded to the charge pipe and operational 1996 Ford Bronco - 20200427 - Original oil dipstick fits, though is now routing up passed the brake booster and pokes up next to the charge pipe now. 1996 Ford Bronco - 20200427 - The first start happened before I got there and I got to start it once after I arrived. So technically this is the third start b…Video 1996 Ford Bronco - 20200429 - Front end is together now. Waiting on a few odds and ends. 1996 Ford Bronco - 20200429 - Intercooler fits nicely. Here I can only see the top half, the rest extends behind the bumper. 1996 Ford Bronco - 20200507 - Here is the final placement of the TPS sensor setup. This is from TCI and is for a 4L60E/4L80E (chevy trans) remote TPS kit. 1996 Ford Bronco - 20200515 - Transmission controller is mounted with a bracket that mounts to the OBDII port location. 1996 Ford Bronco - 20200515 - Transmission controller is mounted with a bracket that mounts to the OBDII port location. 1996 Ford Bronco - 20200515 - Mocked the intake out of titanium 1996 Ford Bronco - 20200515 - Sway bar mounts are getting extended to clear the diesel core support. 1996 Ford Bronco - 20200515 - Sway bar mounts are getting extended to clear the diesel core support. 1996 Ford Bronco - 20200522 - Sway bar drop brackets are gussetted. 1996 Ford Bronco - 20200522 - Sway bar drop brackets are gussetted. 1996 Ford Bronco - 20200527 - Intake is welded up and fits perfectly. Looks like it touches the radiator but it doesn't. 1996 Ford Bronco - 20200529 - Intake is additionally mounted to the AC bracket from DCS. The bracket was drilled and tapped and the intake bolted to it. Alumi… 1996 Ford Bronco - 2020-07-08 - Finished (mostly) and washed. Still cleans up nice! The striping is missing from the rear quarters because of quarter panel wo… 1996 Ford Bronco - 2020-07-08 - The exhaust tip is a 4", much bigger than I thought it'd be. But that's all right, it all worked out in the end. 1996 Ford Bronco - 2020-07-08 - Engine bay glamour shot. 1996 Ford Bronco - 20200710 - Backside of the tachometer gauge in the dash. I read on FSB that there is a glue used that can run, become hard, and somewhat co… 1996 Ford Bronco - 20200730 - Transmission controller installed under the passenger seat against the frame. The angle is different and I'm hoping there will b… 1996 Ford Bronco - 20200730 - Transmission controller installed under the passenger seat against the frame. The angle is different and I'm hoping there will b…