2 Big Broncos 4x4 Technical White Papers

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Take this information for "face value" and use with your own discretion and wisdom.

Description and Reasoning

Why an engine and transmission conversion?

After running many, many miles to Colorado and back in July 2000; Working with the altitude and carburetor adjustments at 10-13,000 feet, experiencing fuel "vapor lock" problems, having fuel splash around on many of the trails, and my second "daily driver" Bronco's engine was dying very quickly... I went ahead with the purchase of a "parts yard" 1996 Ford Bronco with 36k miles. Ended out this Bronco had a good engine, transmission, and most of the OBD-II sensors still in tack. Could not pass up this purchase / upgrade! Also, the transmission in my Bronco was beginning to over-heat in normal driving conditions - as a result from the Colorado return trip I assumed.

The E40D automatic should make this conversion eaiser with the electronics feeding the PCM ("Computer"). Also, the E40D has ... the electronic push-button over-drive and a wide-ratio gear set!! This gives me a lower 1st and 2nd gear for off-road crawing, a high ratio over-drive for highway speeds when I change my ring/pinion from 4.10 to 4.56 in the future. I can have my "cake" and eat it too. I know of a few issues to deal with on the E40D during the conversion.

Physically at least 3" longer the my stock C-6 transmission
Linkage is cable based rather then my stock levers
Oil pan is hugh with a rather large oil sump area -- will need some custom rock protection

Buy/Find The Components

The "New" Engine, Transmission, and Y-pipe Exhaust -- September 10, 2000

1996 351W EFI, OBD-II, Mass-air	Another view point	E40D Transmission
Getting the "experts" to re-wire components	In my service shop	How much work!!

Removing "WildHorses" 351W HO Motor - September 12, 2000

This motor was rebuild in 1992, about 45,000 miles ago. The power and oil pressure have been great. I am replacing the leaky rear main seal (2 piece) and oil pan gasket before installing it into my second 1986 Bronco. The daily driver...

Rade is ready and waiting
Just about removed
A very high pull up
Finished... almost.
Now for the rear main seal

Replacing the leaky
rear main seal
On this motor, it is
a two piece seal
To service this seal
the bearing caps are
loosen and the rear
has been removed

Finished the engine swap into my "Mr Blue" Bronco on September 22, 2000. Now I can focus on the R-E-A-L work at hand!!!!

Ready to Start

On recommendations from my local "EFI Experts", I purchased a few reference materials. These books are considered the best of the best by content and authors.

HELM Publishing, 1996 Bronco Wiring Diagrams. Part# FCS1212996
Ford Fuel Injection & Electronic Engine Control (88-93)
by Charles O. Probst, SAE. ISBN 0-8376-0301-3

On the 1996 351W parts yard engine, I have had help in completing the following maintenance items.

Water pump - replacement of broken unit
192-195deg thermostat - replacement
Oil pan gasket - replacement
Fuel pressure regulator - replacement of damaged unit
Exhaust gasket & JBA header installation - replaced stock manifolds
Air chamber support bracket customization - due to header installation
Powersteering fluid flush & refill - keeping busy
Spark plugs - replacement

Installation of a new
one-piece oil pan seal
Dip stick fits into
engine block

PPG Fire Brick red...
the only color for
WildHorses!
Ford's oil cooler

And yet, the list isn't complete. I have the following items planned for this "new" engine.

Rear main seal - replacement
Distributor cap, rotor, plug wires - replacement
Valve cover gaskets - replacement
Intake, throttle body gasket kit - replacement
Customized belt routing - required due to broken bracket not being replaced
Highoutput Alternator mounting bracket conversion from '86 - required for conversion

Inventory of Items To Purchase

Fuel Lines - from tank to filter, filter to hp pump, return to tank -- est $40
Fuel Pump "kill switch" inside cab -- est $5
TFI Module -- est $80
E40D Large Oil Cooler -- est $45
E40D Custom Oil Lines -- est $30
Automatic Trans Temperature Sending Unit for E40D Oil Pan -- est $15
Air Vent for E4OD -- est $5
Engine Spark Plug Wires from Motorsport 9mm -- est $60
Engine Brackets - belt roller -- est $50
Engine Motor Oil 10w30 (or Syn oil mix) -- est $12 / $24
Exhaust "cherry bomb" style, with tail pipe -- est $60
Digital Multi-meter -- est $75
Rear Drive line Custom 3" shorter for E40D -- est $60
T-25 Torx Bit -- est $15

Inventory of Items Purchased

Description	Estimated Price	Actual Price	Part# Reference
Motor Mounts	$60 (pair)	$58	NAPA #602-1572
Fuel Filter (large) from 1989 Bronco	$10	$9.54	NAPA #3097
Water Pump, reverse rotation	$45	$42.50	NAPA #125-1670
E40D Pan Gasket & Filter	$15	$26.56	NAPA #1-7975
Engine Thermostat 195deg	$10	$4.71	NAPA #269
Engine Spark Plugs	$15	$8.72	Autolite
Engine Distributor Cap, Rotor	$15	$29.18	NAPA #FA134, #FA153
Engine Exhaust Headers Gasket	$45	$26.48	NAPA #95025-SG
Engine Fuel Pressure Regulator	$15	$44.17	NAPA #2-19617
Engine Oil Filter	$5	$5.48	NAPA #1372
Engine Oil Pan Gasket - 1 piece	$??	$30.86	NAPA #OS-32492
Engine Serpentine Belt	$??	$29.84	NAPA #25-061020
HP Fuel Line Tools	$20	$8.95

Inspection and Installation of 351EFI Motor

January 20, 2001

Following a long break-away from the shop, Rade got me started again on Saturday, January 20. He and I replaced the upper intake gasket, throttle body gasket, and both valve cover gaskets. The rear main seal was inspected and decided to keep in place. Motor was the hoisted over and into the Bronco. With no transmission, the insert too two minutes (once we removed the hood).

Upper intake gasket - replacement
Throttle body gasket - replacement
EGR gasket - High temperature Silicone
Valve cover gaskets - replacement
Rear main seal - inspected and kept
Motor mounts - replaced

Valve cover removed
showing excellant
condition of motor.
Upper intake removed.

Inspected rear main seal
and kept it un-touched.
The 351EFI motor
is now in!
Looking real cool.
Needs wiring and much more!

Fuel Tank Low-Pressure Pump
April 2001

Another small side-project is the fuel system feeding the injected 351W motor. My choice was to install a low-pressure feeder pump (in the tank) to a frame-rail high pressure pump feeding the engine's fuel rail. I picked up a used high-pressure pump and miscellaneous wirings and fuel lines from a parts-yard.

I had already made a fuel tank purchase from MTS Company, L.C. Model #4251S which had the correct access hole for a 1987 EFI fuel system. I needed the sending unit, low-pressure pump, and wiring to activate the fuel pump.

Wiring to feed the in-tank
low-pressure fuel pump.
Filler tube and
breather tube.
Installed with return
line in view.

High pressure pump attached
to frame rail.

OBD-II Computer Brains(PCM)
April 2001

A "big deal" sub-project is the computer module for which all OBD-II processing gets handled. I was able to pickup the PCM and wiring harness along with the engine, from the same vehicle.

The location was not much of a choice. Basically the wiring harness REQUIRED me to locate the PCM in the firewall, next to the brake master cylinder. This work required serious cutting, fabricating, sealing and rivet work. I would rather have purchased an injected Bronco before doing this again... something to consider.

I removed the fender to
create easy access
to my work area
Mark the location
of the PCM box
before cutting.
Cut and re-enforced
with rivets.

Container box installed
and PCM with my custom
cover ready.
Finished. Is this
ready for water?

Final look...

July 7, 2001

This was taken shortly before leaving for Northwest BroncoFest 2001 in Kaner Flats campground. It worked great.

Ready just in time
for NW BroncoFest 2001.

Installation of E40D Transmission/BW1345 Transfer case (Extra Project)

January 27, 2001

The E40D was a simple bolt-in on this motor, except for modifications to the cross-member bracket and usage of the C6 transmission mount. This custom setup using a C6 transmission mount and cross-member bracket (from the 1986 configuration) required (REQUIRED!) my 1" body lift for clearance. It fit, but with only 1/2" space between the body and transfer case.

The E40D with my
custom breather vent.
Berne man-handling the
E40D into position.
Another view point
for fitting the tranny in.

Finished Product

The Finished Product Works!

Kurt Hartsig - 1986 XLT Bronco

Reminder... Contact 2-Big Broncos

Rade is ready and waiting	Just about removed A very high pull up	Finished... almost. Now for the rear main seal
Replacing the leaky rear main seal	On this motor, it is a two piece seal	To service this seal the bearing caps are loosen and the rear has been removed

Installation of a new one-piece oil pan seal	Dip stick fits into engine block
PPG Fire Brick red... the only color for WildHorses!	Ford's oil cooler

Valve cover removed showing excellant condition of motor.	Upper intake removed.
Inspected rear main seal and kept it un-touched.	The 351EFI motor is now in!	Looking real cool. Needs wiring and much more!

Wiring to feed the in-tank low-pressure fuel pump.	Filler tube and breather tube.	Installed with return line in view.
High pressure pump attached to frame rail.

I removed the fender to create easy access to my work area	Mark the location of the PCM box before cutting.	Cut and re-enforced with rivets.
Container box installed and PCM with my custom cover ready.	Finished. Is this ready for water?