ONEWYR's build thread

[ONEWYR]

I will bring you up to date and then move on from there.

Here is my list of mods so far
My truck is a 1989 BroncoII it started of as a 2wd model and then about a year and a half ago I cracked a head so I bought a wrecked 4x4 BII with a good motor and swapped motors and drivetrains to convert it to 4x4. This august I picked up a '91 explorer and removed the axles, tcase, motor, and trans. I have already installed the axles and tcase in my truck so now it sits on a D35 and a 8.8" with stock 3.73's and a ford trac lock in the rear. I have done the 58mm TB mod and cold air intake mod it gives better throttle response while in the higher rpm range. I am using a set of 4-6" skyjacker brackets set for 4" right now in the front and explorer springs in the rear with big perches it sets a little high in the front. I have converted the A/C pump to use for on-board air with a pair of custom tanks in the rear. I have extended ProComp brakelines. I recently installed a Power Trax Lockright locker in the front and Warn Jeep hubs. Right now I have a set of 32/11.50/15 sidewinder A/T's on steel wheels. Swapped out the BII buckets for some Eddie seats. I am running a Cobra LTD29 NW w/ wilson5000 antenna. thats all I can think of for know now here are some pics.

[ONEWYR]

Let me start by saying that when I went outside I had every intention on starting my half doors, but when I got outside I figured I would go ahead and trim my fenders like the guy did on BII.org he did a pretty good write up on it so as I started to take the fenders off I started thinking I got this much off whats a few more parts so I decided to go ahead with the gen1 swap.
So far I have everything unbolted all the harness taken loose all that remains is drilling out the 20 or so spot welds and then the gen2 clip is off. Now I am not sure how others have done this swap but I am removing the inner fenders from the firewall not just taking the core support. I already have the Gen1 clip ready to go in just waiting on getting the gen2 out.
I also started to layout the cuts on the fender cause I am gonna trim them before I install them they will have a pretty wicked cut on them getting rid of a lot of metal.
in some of the pictures you will see blue tape I plan on cutting from the tape down meaning after the cut has been made the tape will still be there.
I should have it back together by the end of the week I will take notes and pics incase anyone is interested in the swap.

[ONEWYR]

Today I made some good progress I got the gen2 inner fenders and core support removed and got the gen1 put in I still need to finish bolting the inner fenders to the firewall. When i finish bolting the inner fenders on I will need to address the radiator mounts and trim the fenders before i bolt them back in. i didn't take pics of the inners and core support back on because it looks just like the first pics I took if it doesn't rain tomorrow I will finish bolting the inners back in and do the rad supports and start securing the harness back in place I figure i still have another couple of days and the conversion will be complete.If you do this swap the way I am by swapping inners it is pretty straight forward the biggest pain in the ass is the fact that you have to drill out about 50 spot welds and that is no exageration. here are some pics of all the sheet metal removed from the front.

[ONEWYR]

I didn't get to work on the truck yesterday but today I got off work early and started in on reassembling the front end. I got the inner fenders bolted in and then I took the plastic wheelwells and trimed those and bent them up and screwed the trimmings to the inner fender I will get pics tomorrow cause that is a bit hard to imagine. I had to get the radiator supports relocated for the 4.0L radiator, and then mount the trans cooler I got the cooler plumbed and the radiator all hooked back up. I got all the wires put back where they belong and noticed something cool about all the lights up front on each side of the truck there is a total of 3 light sockets 1 is the head light 1 is the front turn signal and 1 is the side marker light out of the 3 the only rewire i need to do is the head light the plugs don't match up but the other 2 the sockets from the second gen lights will twist in to the gen1 light housings this is cool because now I don't have to rewire all of the lights. I found that i am gonna have to adjust the amount of sheetmetal that I am planning on trimming so it doesn't look stupid if I trim it as much as I had originally planned you will see some of the core support and I don't want that. all I have left is to FINISH hahahaha

[ONEWYR]

I put another 5 hours in today and I am pretty much finished all I am lacking now is 1 spring for the passenger side head light and some coolant. Oh yeah and to fix the harness that I hit with my sawzall I cut through like 3 wires in the bundle so I threw my hands up and said I need a break. anyways here are the pics
here is a pic of how I screwed the plastic wheel well to the inner fender

this is one showing how I mounted the trans cooler

this one shows how much clearance I have since I trimmed the fender


this one shows how I trimmed the lower trim to match the fender

this one is just a pic of the front you can see that i don't have the headlight in cause I seem to have lost it .

I plan on going to the parts store to get the spring and coolant later on. I still need to finish the bumper and rewire the on board air and while I am at it I am gonna go ahead and wire up the lights that sit under the rear bumper.

[ONEWYR]

I will get started on my swap tomorrow. For starters I will be going to my inlaws to weld the towbar brackets onto my bumper so I can move my truck around while it has no motor. Then I will start removing whats left of the porno red interior, that being the dash once that is out I will be trying to build a new dash cause I really don't want to use a stock dash. I am also gonna try and figure out how to scrap all the heater functions accept the defrost and maybe 1 forward facing vent. once the dash is squared away i will be pulling the motor/tranny/tcase and setting it on a trailer once it is out I will keep the good parts I think I can sell and scrap the rest. Pulling the motor should be a sinch cause I am removing the entire front clip and my bumper after all has been removed I will be bolting the new motor/tcase/tranny together and dropping it all in and hopefully the wiring will be easy since I am changing the dash wiring and everything . of course I will be keeping everyone up to date I will probably update every evening after I come in for the day.

If I am missing anything please speak up and if there are any pointers you can offer for the swap by all means say something it will be greatly appreciated

[ONEWYR]

[img width=800 height=600]http://i2.photobucket.com/albums/y23/onewyr/broncoII/1119.jpg[/img]
I haven't updated in a while so here is what I have done since the front clip swap. I repainted the front to match the rear. I got My 34x10.50x15 LTB's they are so much better than the AT's. Last month I went on a couple wheeling trips before the new tires but my tranny has been acting up so I decided to put a rush on the 4.0 swap so I wouldn't miss to many more trips. I have spent the last 2 weekends in the junkyard gathering parts for the swap. Last weekend I manage to pick up a 1354 manual tcase for $100 and this week I pulled a M5od come to find out the input shaft was broke so I went back the next day and pulled a FM146 all I need now is a clutch and I will be set. I would have ordered the clutch last night but I came across a great deal on all craftsman tools $200 got me a new looking 30gallon air compressor, 1/2"impact, 1/2" air ratchet, 3/8" air ratchet, die grinder, blow off tool, 25 foot of hose. These tools are a couple of years old but look brand new. So I figured it would help with the swap and all other work I do on my truck and everyone elses truck


Oh yeah I also picked up a 1995 explorer rear axle disc to disc for $60 pulled and it is 3.73 L/S just like mine so I am gonna install this while I am doing the rest

[ONEWYR]

march 18 2008
I had limited time since I didn't get started till 6:30 but i had the front clip ready to come off and cleaned up in about 45 minutes. tomorrow i will get under the truck and unbolt the dhafts, linkage, motor mounts, and the harness through the fire wall. If I get really desperate I may go ahead and pull the motor/tranny/tcase hopefully as one piece I also need to un kook the exhaust
march19 2008
I had limited time since I didn't get started till 6:30 but i had the front clip ready to come off and cleaned up in about 45 minutes. tomorrow i will get under the truck and unbolt the dhafts, linkage, motor mounts, and the harness through the fire wall. If I get really desperate I may go ahead and pull the motor/tranny/tcase hopefully as one piece I also need to un kook the exhaust
march 20 2008
I got the motor/tranny/tcase out as one piece I had to take the cats off they made it to big to get out so off they came and out the rest came when I put everything back I will only be putting the motor/tranny in as one piece, the tcase is easy enough to install under the truck. I also got the air box off of with a BFH biggrin.gif I am building a new one of those because none of the junkyards have a no ac box. started looking at the fuel lines I am gonna have to change one I think from the fuel filter up to the rail.
march 21 2008
Dash is out and steering colum is out I still need to go pick up another column cause I want a non automatic column. Clutch master cyclinder is installed and all the auto linkage is out alright nuff chit chat back to work
dash is complete, inside i am just lacking the ecu and steering column I have the ecu just not sure which one to use. motor tranny tcase and front driveshaft are all in everything underneith the truck mis done except the exhaust. inner fenders and core support is on. started hooking up some of the harness it isn't going to well I was trying to use the plugs that run the length of the truck and land on the driverside fender and nothing is matching up. So I gotta break out the chiltons and figure out this mess. the fuel lines are not working out either I had read awhile ago that all you had to do was change the line that comes off of the filter but both need to be changed the problem is that the other hose goes straight from the fuel tank to the engine with no joints. I am really starting to wonder what I got myself into, this is turning out to be quite a undertaking. If I had it all to do over again I would not do it. everything is bolting up nicely it's just the wiring that is killing me
March 22 2008
I got it to fire up and boy is that thing loud with NO exhaust just the "Y" pipe. I still need to get the radiator mounted and plumed get a non ac belt , figure out how to get the rear lights to work cause the b2's rear lights were fed from the engine bay and the explorers lights are fed from inside the truck so I gotta figure out what wires I need out of the explorer harness and get them through the firewall and hooked into the b2 part of the harness and then get the speaker wires ran cause the explorer I got the stuff out of had the premium sound system which means no rear speaker wires but I still have the b2 dash so I can rob stuff from it. then I need to bleed the clutch and do the rear axle swap but the axle may just wait till another weekend I gotta go out tomorrow and get a steering column and I should be done with the swap
oh yeah I was making a big deal out of nothing with the wiring just make sure you take pictures of everything in the donor I didn't and the last time I saw the dam thing was six months ago so I saw all this extra shit and started to freak so I went and saw my buddies at the junkyard and went back and found an explorer like mine and took many pics and that helped alot
alright here we go I am gonna post some pics and maybe you guys will get off my back about pics, You pic whores. I am gonna do a write up later may take me a week or so to do the write up but I will do one.
here is the tranny I used FM146

here are a few as I am dismantling the front end





here are a few when I was doing the clutch master cylinder you can see the plate that I removed that was covering the hole for the cylinder I had drilled holes in it way back when and this is where the temp guage was routed.

[ONEWYR]

March22 2008 continued
continued
here are a couple comparison shots of the pedal assemblies


here are a couple after I installed the pedal assembly and no dash.




new dash installed

and the motor in it's new home




here are some more pics of todays progress.
this is the no ac heater box

here is the old column after I pulled it

Here is the 4.0 intake hose and a 90 something ford taurus 3.8L maf this is a direct bolt on that allows you to use a cone filter

[johnpaulgolf]

WOW you've been working hard...great progress keep us posted...looks really good