Hey guys, My brother has a 96 Bronco and want to start modding. His order is a little off so I want to get him on track. Just Did this weekend-4" suspension lift, 40" Dick Cepeks,2.5" cat back w/Magnaflow muffler to duals, and he just ordered his Brushwacker flares. He needs a cold air intake and chip. What to go with? I've got a 7.3 diesel, went with AFE and DP Tuner, no help to him. Suggestions? By the way I'll get him to join here. Thanks

 

He needs new gears. I would sudgest 4.56 or lower. While your in the diffs, I would put some lockers in it. I would think about a full-floater kit and axle truss in the back also.

 

I agree with all the above, but I'm still trying to find the best air intake and chip. Anybody? Bump Bump

 

Holy crap! If thats a stock 96 it has a Dana 44TTB and the Ford 8.8.
Both good axels for anything under 38inch tires. You can run bigger tires and get down the road but dont try any hard off road driving. The axels are not big enough for the torque loads.

 

Here's my 95 Bronco on Procomp ATs 35inch and stock axels. This is a video of my rescue and repair after breaking the sector shaft on the steering box Forth of July week end on the John Bull Trail.
YouTube - John Bull Trail July 6 2008

 

Ditto to rudedogii's comments. The D44 and the 8.8 are great axles but not for that much meat. You'll end up breaking U-joints and replacing ball joints up front more often than you care to think about unless the truck is gonna be a showpiece and nothing more. The 8.8 might handle 'em a bit better but that's a lot of unsprung weight to be slinging around. under 1/2 ton suspension.

 

X a bizzilion 40s on stock axles is carnage waiting to happen. How much did you have to cut out of the fenders to make them fit?

Stock air box with a drop in K&N is better than almost al overprices hot air intakes out there. Do not worry about a chip until you get the right power to those tires.

 

Yea he knows his axles aren't going to make it. He's looking to roll a pair of 60's under it, and do the gearing (4:56) at the same time. His 40's are actually measuring 37.5". Not that thats much better. I told him to go with a drop in K&N and forget the chip. Thanks for the replies guys, big help.

 

He said they had to cut a little off front and rear of front fenders, and trim the bumper a bit also. The rear he cut about 2.5" to 3", front and rear, tapered in up to about a foot up. I'll try to post a couple of pics if I can.

 

Looks Like I'm not allowed.

 

You can link to them. AND WhyTF would you put 60s under a Bronco?

 

Oh I dunno wileec, I've seen Early Bronco's outfitted with D60's by guys who just can't stay out of the places that would otherwise eat 1/2ton axles for lunch. Admittedly, they look a little silly with full width axles sprouting from the wheel wells and the tires beyond the fenders. At least a Big Bronco can handle such a mod without looking too much like a roller skate.

 

Crap I feel stupid I know quite a few broncos that are running 1 ton axles. Both old and new. When I read 60s I was thinking tires

I run with a guy who has 60s and a shaved soon to be 8" shaved EB. That thing goes...
as an example

 

Hey guys, He would also have the 60's fitted for width. Can you say custom.