I bought my poor 1996 Bronco in December 1995 and it has thrived on oil changes and neglect for a long time. Now it's got just over 240k miles and could use a little more attention.

I've found a lot of good info in this forum already, maybe I can get a fairly recent lead on some part vendors or "since you are already in there - you may want to do this too" type ideas.

1. Interior driver bucket seat is broken. Frame has a crack in it that could probably be welded. When seat in most upright position still leans back. (I was rear ended on I-35 on the way to drill at 4AM a few months back. I had cruise locked at about 65 and the impact was enough to total the Volvo that hit me. Impact snapped the drivers seat too.)

2. Two front bucket seats upholstery is shot. Need to find someone to recover them. Or have also been thinking to replace 2 front buckets with a 40/60 split bench so I can seat 6 now that I have 2 little helpers. Can't take wife, 2 kids, and 2 grandparents in 1 vehicle. Bronco Graveyard didn't seem to have the selection I wanted. Local salvage yards haven't turned up anything either yet. I don't want to spend a lot on the seats.

3. Rear bumper. I'd like to put a heavier duty rear bumper on that has a class 3 receiver hitch. Same impact that ruined my driver seat curled my bumper under. I could probably hammer it straight but would need to replace the broken brackets. Local 4x4 specialty shop doesn't have anything for slightly older vehicles. May just get someone to weld me something up.

4. Passenger window won't roll up. It's electric. May need to replace the motor. I gave it a 10 minute look once and it didn't look like an easy job. Maybe I just didn't look hard enough.

5. Gas leak. I think there is a poor seal where the fuel pump goes into the top of the gas tank or maybe it's the vent line. It's ok as long as I don't try to fill the truck up too full.

I probably have a few more I can't remember while I have a 2 1/2 year old using me for a climbing gym.

 

As for the seating, any bucket or bench seat from another Bronco or F-series of relatively the same vintage will bolt right in. (Yes, the floor of the Bronco has the tapped holes for the bench seat as well, you just have to dig out the plugs and the undercoating that block them up). You will need the ENTIRE seat including all of the slide and adjustment hardware between the actual seat(s) and the floor.

If replacement isn't an option, there are several high quality seat covers available for the seats in these trucks. You would just need to repair any missing padding before you put them on over what is left of the old seat cushions.

If you want a Class III hitch, get one from a local towing supply house and just put whatever bumper you like on the truck. A good Class III will bolt to the bottom of the frame and come out just under the bumper anyway. Well, mine from Penske does. Can't recall the hitch brand off the top of my head. Just my personal suggestion. Its up to you.

Before you get into the headache of replacing the window motor, pull the switches and clean them well with electrical contact cleaner (Radio Shack). I am going to assume the window does not respond to either switch. Make sure the motor isn't running or "humming" which indicates it is stalled either from something blocking the window or crud gumming up the mechanism.

Ugh, with the fuel pump/sender, if you do end up having to replace it you either have to drop the tank or cut an access hole (and then fabricate a cover) in the cargo area floor to get at it.

 

About the window mechanism, first of all, try the Neardenthal approach: Take the door trim an hit the moving parts firmly but with care enough not to damage or bend anything, using any metal tool of some weight (i used a mace i carry around). Sometimes the mechanism is just stuck, do that and try using the switch to move the window, if it releases itself, just lube the internals with graphite grease and reinstall the trim.

My seat frame also cracked, i welded it a year ago... haven't heard any complains from it again.

 

I finally got the frame welded. It' amazing how a wife and 2 kids can commandeer any time I reserve for working on my projects.

 

There's some pictures in my album of the fuel tank and the filler inlet hose. I think that would be a more likely source of the leaking. Or it might be a vapor valve on the top.

If you decide to drop the tank, there's 8 bolts, an impact wrench makes short work of it.

 

I wasn't able to find the tank pictures but I will admit (embarrassingly) that the leak started after me and 2 buddies from work dropped the tank and replaced the fuel pump. Yes, a borrowed impact wrench was awesome. I noticed the leak the next time I filled up and we never got a chance to reschedule - then the company we worked at moved 200 miles and scattered us to the wind.

Anyway, I'm betting on the vapor valve up on top. I guess since 3 of us worked on it the 1st time I've been hesitant to tackle it solo.

I've been hinting to Mrs Claus that a compressor would be awesome to have so I have my fingers crossed.

 

This link should get you there,

Ford Truck Enthusiasts Forums - g_k50's Album: Garage - DonKo - Picture

The filler hose is pretty easy to inspect, just look from underneath it's all visible.

The hole for the vapor attachment can be seen in a photo of the tank while out and being cleaned. It's about 1" dia, and in the center of the tank top. It has a O-ring gasket and that might be what's missing.

 

I have a 94 XLT Bronco that is in real good condition. My bronco needs qa torque convertor(per the local Ford store). The interior is good, leather is decent, door panels excellent, body has no rust, it has the trailering package. the original window sticker on this truck is over $29k. it has 187000 miles on it. has remote keyless entry, power everything. Priced to sell. give me a call at 276-358-1096 if interested. i cal furnish a lot of pictures if interested.
Bill

 

96 bronco,
I may have missed something, but wanted to voice a concern. Did the gas leak/smell start after the rear ending? The way I read the thread, the gas tank drop came before the wreck. If they came close together, the wreck and drop, is it possible that maybe something was punctured on the tank after the wreck? Just a small concern of mine that there may be a different problem than you suspect, i.e. vapor valve or "o" ring. Mark

 

Thanks Mark. Really appreciate that. But I think the tank is ok. Timing was the fuel pump was swapped out 1st and the leak detected. Then recently the truck was rear ended.

When the truck was rear-ended the bumper pivoted down and the bottom of the trailer ball put a ding in the skid plate but the intensity of the leak did not increase. As long as I only add about 16-17 gallons I don't smell anything.

 

Thanks Bill. It sounds like a great truck but my wife will absolutely kill me if I buy another vehicle.