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  #1  
Old 08-10-2010, 04:27 PM
jfritts jfritts is offline
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90 Bronco 4BT Diesel Build

I got a 1990 Eddie Bauer bronco with 240k miles on her. Had a 351w that had a few mods but I was getting 10mpg on a good day and just wasnt happy with it. Decided it was time for a diesel and ZF-5 swap to beef up my drivetrain and get some better mpgs out of her.

What I started with:
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Bought me a 86 Chevy P-30 step van with a 4bta. Couldnt find a buyer for the van so it got the axe and the rest got sold for parts.

Scrapping:
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Overall about 1800lbs of aluminum and 2000lbs of steel.

What 1200lbs of steel looks like in a bronco:
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Old 08-10-2010, 04:32 PM
jfritts jfritts is offline
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Pulling the 4bta:
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Safe in my very crowded garage:
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Found a ZF-5 S-42 from a member on 4btswaps.com.
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Parts hauling in my wifes car
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Got a stock step van 4bt to small block ford adapter setup. Included adapter plate, flywheel, starter, clutch, pressure plate, and master cylinder. I ended up getting a new clutch, pressure plate, and master cylinder just to be safe tho.
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Starter had been ground a bit for clearance i guess
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Old 08-10-2010, 04:37 PM
jfritts jfritts is offline
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At the time I thought I could do the swap in a week sooo I took a week off from work. My brother and I got started by tearing my bronco apart.

Engine out:
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Transmission and tcase pulled. Goodbye E4OD!
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My workspace, apartment complex parking lot. Definitely not the recommended spot for a engine swap and we will touch on that more later.
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Empty space
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Cleaned up and repainted
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Had the drivetrain out in one day. Thought I was making good progress but I only had downhill to go.
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Old 08-10-2010, 04:44 PM
jfritts jfritts is offline
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Pulled the engine outside to degrease it and put on some fresh Cummins beige paint.

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Painted the exhaust manifold as well
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Found out the ZF-5 needs a different crossmember so it was back to the junkyard.

ZF-5 in her new home, held in by only a ratchet strap and resting the crossmember on the frame.
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Tuesday morning I woke up to no bronco. Apartment complex cracked down on my work and had her towed. Lucked out because my transmission didnt fall out while being towed.

Picking it up from the impound lot, This is also the fastest way to get more lift
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Had it towed to the hobby shop on base. Probably where I should have started in the first place.
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Old 08-10-2010, 04:53 PM
jfritts jfritts is offline
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Started mounting the flywheel and clutch up to the engine. Tip for other people, The chevy flexplate has a adapter on the back of the 4bt which just comes off with a few taps of a hammer. No reason to start freaking out because your flywheel doesnt fit

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Testing the fit for the 4bt and mocking up motor mounts. Ended up using the stock mounts that bolt to the engine and then some 300 I6 mounts. Had to get a bushing from Autozone and then some grade 8 bolts.
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Mated up to the transmission
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Hood clearance is a little close
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All bolted in. It was a PITA getting it lined up and both sides bolted down
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tons of room in front. Plenty of space for a very very large intercooler
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Tried using the hydroboost setup from the chevy stepvan but it was nothing but hassles.
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Ended up pulling a new hydroboost setup from a later 90s early 2000s model truck and used that.
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The failboost
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All bolted up:
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Old 08-10-2010, 04:57 PM
jfritts jfritts is offline
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For the fuel system I pulled out the intake pump and pulled all the stock EFI lines. Then I just ran a pickup line into the tank and new lines all the way up to the engine.
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Finally got a third pedal in my rig!!
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Engine must have moved the ZF-5 back some because I was able to retain my stock driveshaft. I havent tried to put the front one back in yet but time will tell.
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Old 08-10-2010, 05:00 PM
jfritts jfritts is offline
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Few random pics:
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Order some gauges from summit racing. Boost, oil pressure, and exhaust gas temp. Along with a A-pillar gauge pod.
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Old 08-10-2010, 05:03 PM
jfritts jfritts is offline
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Picked up a stock dodge intercooler. For reference it is leaning against a 38 inch tire.
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Future mods to the engine include: 3200rpm spring, dennyt fuel pin, intercooler, turbo from a 6bt.

I got it all back together and driveable in 25 days. Runs pretty good and has plenty of power once the turbo spools up. All i have left is cleaning up my wiring mess, hooking up my a/c and heater.
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Old 08-10-2010, 10:38 PM
helirich helirich is offline
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So your running it completly stock and it is comparable to the 351? Or did you allready do the mods? What did you do for a A/C compressor mount?
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90' Bronco, 351, MSD Ign., SS 3" exhaust,
38" x 15.50 R15 Dirt Grips, 14" x 15" Alcoa wheels
6" lift w/ cutout flares, 40 gal. fuel tank
F diff - lockright locker, 4.88's
R diff - Powertrax locker, 4.88's
Cast diff cover w/ carrier braces
Rear full float axles, truss, Above spring traction bars
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Old 08-10-2010, 10:44 PM
jfritts jfritts is offline
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Yea its stock for right now. Id say off the line it is slower but once it gets some boost built up then its about the same. I also switched transmissions so my gear ratios are different than before. I am sure that after a few mods (fuel pin, rpm spring, and intercooler) it will be faster. And with a new turbo it will be a lot better. I havent mounted my A/C yet. It is just laying in the engine bay.
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  #11  
Old 08-12-2010, 08:57 PM
jfritts jfritts is offline
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Boost and Pyrometer in the A-pillar
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Oil Pressure where the overdrive switch use to be
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Also finished mounting up my temporary exhaust until the new turbo gets installed. Runs out right before the passenger rear tire.
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  #12  
Old 08-13-2010, 12:37 PM
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American Thunder American Thunder is offline
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Looks good so far!
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1978 Bronco - 12V Cummins power, pump mods, Dynamic Racing Transmissions C6 automatic, Billet 1200 rpm converter, Destroked adapter and billet flexplate, NP205 t-case, 9" lift, 35s, 3.50 gears, upgraded brakes and braided hoses, 4" exhaust - no muffler. GOT TORQUE?
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Old 08-15-2010, 10:09 AM
helirich helirich is offline
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Where did you put the sensors for pyro and boist? As I understand it, you only have the fuel pump on the engine? (none in the tank or inline)
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90' Bronco, 351, MSD Ign., SS 3" exhaust,
38" x 15.50 R15 Dirt Grips, 14" x 15" Alcoa wheels
6" lift w/ cutout flares, 40 gal. fuel tank
F diff - lockright locker, 4.88's
R diff - Powertrax locker, 4.88's
Cast diff cover w/ carrier braces
Rear full float axles, truss, Above spring traction bars
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Old 08-15-2010, 02:01 PM
jfritts jfritts is offline
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For the boost you just pull one of the plugs below the intake. I will grab a picture today. I havent mounted the sensor for the pyro yet but it will go about 5 inches behind the turbo.

Right just the pump on the engine
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Old 08-15-2010, 03:25 PM
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BigPigDaddy BigPigDaddy is offline
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You sure made that look easy!

What kind of RPM are you running at highway speed? Any plans to change gearing?
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Old 08-15-2010, 03:25 PM
 
 
 
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