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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.
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
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.
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.
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.
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.
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.
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.
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