90 Bronco 4BT Diesel Build - Ford Truck Enthusiasts Forums



1978 - 1996 Big Bronco SPONSORED BY:

90 Bronco 4BT Diesel Build

Reply
 
 
 
LinkBack Thread Tools Search this Thread
  #1  
Old 08-10-2010, 04:27 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
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:





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:






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

What 1200lbs of steel looks like in a bronco:
Reply With Quote
  #2  
Old 08-10-2010, 04:32 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
Pulling the 4bta:



Safe in my very crowded garage:


Found a ZF-5 S-42 from a member on 4btswaps.com.




Parts hauling in my wifes car


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.




Starter had been ground a bit for clearance i guess
Reply With Quote
  #3  
Old 08-10-2010, 04:37 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
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:


Transmission and tcase pulled. Goodbye E4OD!


My workspace, apartment complex parking lot. Definitely not the recommended spot for a engine swap and we will touch on that more later.


Empty space


Cleaned up and repainted



Had the drivetrain out in one day. Thought I was making good progress but I only had downhill to go.
Reply With Quote
  #4  
Old 08-10-2010, 04:44 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
Pulled the engine outside to degrease it and put on some fresh Cummins beige paint.






Painted the exhaust manifold as well


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.


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



Had it towed to the hobby shop on base. Probably where I should have started in the first place.
Reply With Quote
  #5  
Old 08-10-2010, 04:53 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
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



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.



Mated up to the transmission


Hood clearance is a little close


All bolted in. It was a PITA getting it lined up and both sides bolted down


tons of room in front. Plenty of space for a very very large intercooler


Tried using the hydroboost setup from the chevy stepvan but it was nothing but hassles.



Ended up pulling a new hydroboost setup from a later 90s early 2000s model truck and used that.


The failboost


All bolted up:

Reply With Quote
  #6  
Old 08-10-2010, 04:57 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
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.


Finally got a third pedal in my rig!!


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.
Reply With Quote
  #7  
Old 08-10-2010, 05:00 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
Few random pics:





Order some gauges from summit racing. Boost, oil pressure, and exhaust gas temp. Along with a A-pillar gauge pod.







Reply With Quote
  #8  
Old 08-10-2010, 05:03 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
Picked up a stock dodge intercooler. For reference it is leaning against a 38 inch tire.



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.
Reply With Quote
  #9  
Old 08-10-2010, 10:38 PM
helirich helirich is offline
Posting Guru
 
Join Date: Apr 2006
Posts: 1,274
helirich is starting off with a positive reputation.
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?
Reply With Quote
  #10  
Old 08-10-2010, 10:44 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
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.
Reply With Quote
  #11  
Old 08-12-2010, 08:57 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
Boost and Pyrometer in the A-pillar


Oil Pressure where the overdrive switch use to be


Also finished mounting up my temporary exhaust until the new turbo gets installed. Runs out right before the passenger rear tire.
Reply With Quote
  #12  
Old 08-13-2010, 12:37 PM
American Thunder's Avatar
American Thunder American Thunder is offline
Elder User
 
Join Date: Apr 2009
Location: Upstate New York
Posts: 725
American Thunder is gaining momentum as a positive member of FTE.
Looks good so far!
Reply With Quote
  #13  
Old 08-15-2010, 10:09 AM
helirich helirich is offline
Posting Guru
 
Join Date: Apr 2006
Posts: 1,274
helirich is starting off with a positive reputation.
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)
Reply With Quote
  #14  
Old 08-15-2010, 02:01 PM
jfritts jfritts is offline
Junior User
Thread Starter
 
Join Date: Aug 2010
Location: Virginia Beach
Posts: 88
jfritts is starting off with a positive reputation.
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
Reply With Quote
  #15  
Old 08-15-2010, 03:25 PM
BigPigDaddy's Avatar
BigPigDaddy BigPigDaddy is offline
Postmaster
 
Join Date: Sep 2007
Location: OR
Posts: 2,623
BigPigDaddy is a splendid one to beholdBigPigDaddy is a splendid one to beholdBigPigDaddy is a splendid one to beholdBigPigDaddy is a splendid one to beholdBigPigDaddy is a splendid one to beholdBigPigDaddy is a splendid one to behold
You sure made that look easy!

What kind of RPM are you running at highway speed? Any plans to change gearing?
Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
My 79 crewcab build thread (56K pics inside) ranger429 1973 - 1979 F-100 & Larger F-Series Trucks 236 01-01-2016 07:50 AM
New Pics: 1994 Bronco Eddie Bauer Big_Rob S. California Chapter 3 05-31-2013 01:34 PM
E4OD refresh jowens1126 1978 - 1996 Big Bronco 5 03-22-2013 08:41 PM
Bronco gets a new floor pan. AbandonedBronco 1978 - 1996 Big Bronco 8 11-14-2011 09:49 AM
Bronco gets new wheels.... 1979_Explorer 1978 - 1996 Big Bronco 6 05-27-2010 06:57 AM


Go Back   Ford Truck Enthusiasts Forums >

Tags
1996, 4bt, bronco, bt, c6, diesel, f250, flywheel, ford, ii, p30, step, swap, van, work

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Forum Jump


All times are GMT -5. The time now is 10:38 AM.


This forum is owned and operated by Internet Brands, Inc., a Delaware corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford Motor Company or its related companies in any way. FordŽ is a registered trademark of the Ford Motor Company.