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FORD BRONCO
-> ENGINE & COOLING; swaps, specs, snorkels, vac. diagrams...
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WELCOME to MIESK5's BIG BRONCO LINKS - We now have over 30,000 LINKs!
This is a 4x4 Big Bronco, Truck & Van Technical & Parts LINKS site developed by the MIESK5 Family & is not affiliated with the Ford Motor Co. in any manner. Although we initially developed this site for 78-96 Big Broncos, information in many Links also applies to F, E Series & Cars
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ENGINE COOLING
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6 Cylinder - also see Swaps
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Availability of New Silicone Gasket & Sealant TSB 98-7-4 for 84-96 Bronco; 84-98 Econoline, F-150, F-250 HD, F-250 LD; 84-99 Super Duty F Series, etc.
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Belt & Pulley
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Camshaft
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Carbon Deposits
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Casting Numbers
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Compression
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Crankshaft & Main Bearings
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Cylinder Head & Valve, Push Rod
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Diesel
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Dimensions & Weights
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Dipstick
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Flex Plate (Auto Tranny) & Flywheel (Manual Tranny)
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Ford Motorcraft® (fordinstallersupport.com) - Remanufactured Transmissions & Engines - Dual Brand, Broncos & all Ford (32MB pdf)
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Ford Motorcraft® (fordinstallersupport.com) - Remanufactured Transmissions & Engines - Motorcraft® Brand, Broncos & all Ford (19MB pdf); Halli wrote on 30 DEC 2010 that For a Ford Reman 5.8l long block it is 2308.00 exchange. 2210.00 for a 5.0; These are Ford dealer prices in the Mid-South Reman 5.0 = $1914.56
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Freeze Plug
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Gasket Removal TSB 93-23-14 for 88-93 Bronco, F Series, Aerostar, Econoline & many others
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General Engine Repair Practices & Service Tips TSB 92-25-2 for 88-93 Bronco, Aerostar, Econoline, F Super Duty, F-150-350 Series, Ranger; 88-90 Bronco II; 91-93 Explorer, etc.
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General Information
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Harmonic Balancer
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Intake - Filter, Manifold, Snorkel
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Knocking Noise May Occur when Engine is Cold and under Acceleration could be coming from the Secondary Air Injection (AIR) Pump TSB 96-7-27 for 95-96 Bronco, Econoline & F Series
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Leaks
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Mount
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Noise, Vibration, Harshness, Ride, Squeak & Rattles TSB 99-11-1 for 95-97 F 250, F 350, SD; 95-99 Econoline, Explorer, F 150, F 250, Ranger, Villager, Windstar and Many Others, Except that Ford Left Out Our Bronco
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Normal Oil Consumption TSB 89-09-10 for 86-89 Bronco & All Light Truck & Car Lines
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Oil Filter & Cooler
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Oil Pan
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Oil Pump
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Piston & Rod
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Rear Main Seal
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RTV Sealer Limited Shelf Life TSB 90-1-8 for 88-90 Bronco, Aerostar, Bronco II, Econoline, F-150, F-250, F-350, Ranger; 88-90 C Series, Cargo Series, F & B Series, L Series, etc.
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Sea Foam® Process
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Skid Plate
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Specifications
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Supercharger & Turbocharger
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Swaps
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Timing Chain
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Tool Box
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V 8 - also see Swaps
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Vacuum Line Routing Diagrams
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Valve Cover
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Identification Based on VIN, Door Jamb Label, Build Sheet (Ford 999 Report), Paint Color Code, VECI Label, Transmission/Differential Pan & Gasket Sizes/Shapes, etc.; "... made a mistake 15 years ago by telling someone to use the Driver's side label to ID their Rear Differential (axle, pumpkin type, etc.); turned out that a previous owner had swapped a Dana 60 in place of the stock 8.8..."
Source: by miesk5 at FSB
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Identification Based on VIN, Door Jamb Label, Build Sheet (Ford 999 Report), Paint Color Code, VECI Label, Transmission/Differential Pan & Gasket Sizes/Shapes, etc.; "... made a mistake 15 years ago by telling someone to use the Driver's side label to ID their Rear Differential (axle, pumpkin type, etc.); turned out that a previous owner had swapped a Dana 60 in place of the stock 8.8..."
Source: by miesk5 at Ford Bronco Zone Forums
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Identification Label Depiction & Legend, 1980 shown. "...The label is found on the front of the valve cover on the 4.9L; on the front of the right valve cover on V8 engine..."
Source: by Chilton
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Identification, 5.0 & 5.8 EFI; "...EGR - They use different exhaust tubes to connect the EGR to the exhaust. The 5.0L gets exhaust from the lower intake, while the 5.8L gets exhaust from the passanger exhaust manifold. The positive ID is to measure the lower intake; 302 is aprox ~ 8 inches wide. 351 is aporx ~ 11 inches wide. The 5.0L uses squared ports and the 5.8L uses oval ports. If you get an intake from a junk yard it will have the matching fuel rail..."
Source: by Ryan M (Fireguy50) at FSB via web.archive
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Identification, 5.0 & 5.8; "...quick ID tip: The lower thermostat housing bolt on the 302 will be below the top of the water pump and you won't be able to put a socket on it. On the 351W you can remove the bolt with a socket. The positive ID is to measure the lower intake; 302 is aprox ~ 8 inches wide. 351 is aporx ~ 11 inches wide. The 5.0L uses squared ports and the 5.8L uses oval ports. If you get an intake from a junk yard it will have the matching fuel rail..." Read More
Source: by fordification.com & Ryan M (Fireguy50) via miesk5 at Ford Bronco Zone Forums
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Identification, 5.0 & 5.8; look at the EGR Tube; The 5.0 EGR Tube runs from the lower intake manifold to bottom of EGR Valve. 5.8 EGR Tube runs from the passenger exhaust manifold to bottom of EGR Valve. see pics and read more
Source: by miesk5 at Ford Bronco Zone Forums
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Identification, Windsor/Cleveland engines. "...The most obvious external difference is the engine valve covers. The 351W (Windsor) valve covers are attached with 6 bolts, straight front to rear, and narrow in width (similar to the 302 c.i. engine.)* The 351C (Cleveland) valve covers are attached with 8 bolts, flat with 2 different planes, and wider in width. The 351W engine has a radiator hose that attaches to the intake manifold, while the 351C attaches to the engine block. (See Graphic 1 on next page). The 351W takes a 5/8” thread spark plug and the 351C takes a 14mm thread plug. (See Graphic 2 on next page). Distributor differences: The 351W has a smaller 1.245” diameter distributor gear, and the 351C has a larger 1.418” diameter distributor gear. Each engine has a 5/16” oil drive at the bottom of the shaft and a 1.557” diameter housing, measuring directly above or below the O-ring area. *The Ford 302 c.i. engine has a ¼” oil drive on the shaft, a small 1.245” diameter gear, and a smaller 1.550” diameter housing. Windsor 351 V-8 Engine: 1. Valve cover is held in place by 6 bolts. 2. Radiator hose connects to water neck on.." The 351 Cleveland's radiator hose attaches to the radiator and connects directly into the front of the engine block. It makes a 90° bend from the radiator to the engine block.Cleveland 351 V-8 Engine:1. Valve cover is held in place by 8 bolts. 2. Radiator hose is a 90° hose that connects directly to the top front of the engine block..." see diagrams
Source: by CARDONE® cardone.com
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Build Date Stamp Location in a 96; "...The vehicle build date stamp is a four-digit number representing month and day of manufacture. On Bronco and F-150, F-250, F-350, the vehicle build date is stamped on the front surface of the radiator support on the passenger's side of the vehicle. For example, for a build date of January 24, the vehicle build date stamp reads 0124; for a build date of October 21, the vehicle date stamp reads 1021. Yellow ink is normally used for the date stamp. When the marking surface is painted the body color, the date stamp will be marked in red ink. Units from the Ontario Truck Plant (Code C) will be marked with silver ink..."
Source: by thedieselstop.com
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Chilton Manual for 66-81 Bronco, Scanned Copy
Source: by Chilton via broncocity.com
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Detonation & Pre-Ignition (or Pinging); "...Check for over-advanced ignition timing. Too much spark advance can cause cylinder pressures to rise too rapidly. If resetting the timing to stock specifications doesn't help, retarding the timing a couple of degrees and/or recalibrating the distributor advance curve may be necessary to keep detonation under control. A knock sensor can usually be tested by rapping a wrench on the manifold near the sensor (never hit the sensor itself!) and watching for the timing change while the engine is idling. If the timing fails to retard, the sensor may be defective -- or the problem may be within the electronic spark timing control circuitry of the computer itself. To determine the cause, you'll have to refer to the appropriate diagnostic chart in a service manual and follow the step-by-step test procedures to isolate the cause. Sometimes a knock sensor will react to sounds other than those produced by detonation. A noisy mechanical fuel pump, a bad water pump or alternator bearing, or a loose rod bearing can all produce vibrations that can trick a knock sensor into retarding timing. The Exhaust Gas Recirculation (EGR) system is one of the engine's primary emission controls. Its purpose is to reduce oxides of nitrogen (NOX) pollution in the exhaust. It does this by "leaking" (recirculating) small amounts of exhaust into the intake manifold through the EGR valve. Though the gases are hot, they actually have a cooling effect on combustion temperatures by diluting the air/fuel mixture slightly. Lowering the combustion temperature reduces the formation of NOX as well as the octane requirements of the engine. If the EGR valve is not opening, either because the valve itself is defective or because its vacuum supply is blocked (loose, plugged or misrouted vacuum hose connections, or a defective vacuum control valve or solenoid), the cooling effect is lost. The result will be higher combustion temperatures under load and an increased chance of detonation. Try a higher octane fuel. Check for over-advanced ignition timing. Read" your spark plugs. The wrong heat range plug can cause detonation as well as preignition. If the insulators around the electrodes on your plugs appear yellowish or blistered, they may be too hot for the application. Try the next heat range colder spark plug. Copper core spark plugs generally have a broader heat range than ordinary plugs, which lessens the danger of detonation. Check for engine overheating. A hot engine is more likely to suffer spark knock than one which runs at normal temperature. Overheating can be caused by a low coolant level, a slipping fan clutch, too small a fan, too hot a thermostat, a bad water pump, or even a missing fan shroud. Poor heat conduction in the head and water jackets can be caused by a buildup of lime deposits or steam pockets (which can result from trapped air pockets). Check for a lean fuel mixture. Remove carbon deposits. Low coolant level, slipping fan clutch, inoperative electric cooling fan or other cooling system problem that causes the engine to run hotter than normal. READ MORE..."
Source: by Bob at misterfixit.com
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Diagnostic Index, Routines, Symptom Flow Charts, Subroutines, Diagnostic Trouble Code (DTC) Charts & Customer Information Worksheet in a 94
Source: by thedieselstop.com
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Engine Codes in an 82
Source: by miesk5 at Ford Bronco Zone Forums
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Engine Codes in VIN Decoder Chart for 81-86 & 87-96 Bronco & Ford Trucks BEST!
Source: by lmctruck.com
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Engineering & Casting Numbers Overview, Ford
Source: by fordsmallblock.com
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Families of Ford Engines
Source: by Johnny (Bronco Killer) at 7879blueovalbronco.com
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General Engine Specifications in 96 Bronco & F-Series from 1996 All F-150, F-250, F-350, F-Super Duty and Bronco Vehicles Equipped with 4.9L, 5.0L, 5.8L or 7.5L Gasoline Engines, & 7.3L Diesel Engines Workshop Manual
Source: by thedieselstop.com
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History; Engine, Transmission, Drivetrain
Source: by Seattle FSB (SeattleFSB) at FSB
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Is That Water in My Engine Oil?; "...rusty, yellow and foam indicates that somehow the radiator fluid got inside the engine..."
Source: by gotengines.com
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Leak Detection with UV/blue light, General (mostly ad, but good DIY info tips)
Source: by tracerline.com
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Low or Erratic Oil Pressure Readings Repair Tip in 87-88 Bronco & Ford Trucks w/ 4.9, 5.0, 5.8, & 7.3; "...If you run across one of these vehicles that is equipped with a gauge which reads low or erratic oil pressure, here is something to keep in mind. These vehicles do not really have what we would call a conventional oil pressure gauge. The sending unit that is used is not a variable resistance unit. It is merely an On-Off switch. There is a fixed resistance in the dash gauge that will cause the needle to deflect a certain amount regardless of the actual oil pressure. So, it does not matter how high or low the pressure, in any case, the gauge will read the same, as long as
there is sufficient oil pressure to close the switch. Any time there is a question of oil
pressure, the first step is to ignore what the gauge reads and verify the oil pressure with a mechanical gauge. Once you have eliminated a mechanical problem, then concentrate on the electrical part. On these vehicles, if you have eliminated the mechanical problem, and, have replaced the oil pressure sender with no improvement in the gauge reading, Ford recommends that you use a 20 ohmresistor in line between the sending unit and the gauge. Installation of the resistor will stabilize the gauge reading and
eliminate the customer concern..." MIESK5 Note, see how to install the resistor in Link by Steve83
Source: by Bob R at carquest.com via web.archive.org
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Maintenance & Lubrication in a 96
Source: by thedieselstop.com
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National Institute for Automotive Service Excellence (ASE) Study Guide
Source: by freeasestudyguides.com
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No Crank, No Start, Stops Running, Backfires, Hesitation, Misfires, Knocks or Rattles, Poor Fuel Economy, Idle Problems, or Shifting Problems Diagnostic Worksheet
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Noise, Vibration, & Harshness Diagnostic Location Diagram & Worksheet
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Noise, Vibration, & Harshness Inspection and Verification, w/Diagnostic Location Diagram & Worksheet
Source: by thedieselstop.com
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Oil Fill Capacities in 1.9L, 2.3L, 2.9L, 3.0L, 3.8L, 4.0L, 4.6L, 4.9L, 5.0L, 5.8L, 7.0L, 7.3L Diesel, 7.5L with Oil Filter Change TSB 90-22-12 for 91 Bronco, F & B Series, Aerostar, Econoline, Explorer, F Super Duty, F-150-350 Series, Ranger; Continental, Cougar, Mark VII, Sable, Topaz, Town Car, Tracer, Escort, Mustang, Probe, Taurus, Tempo, Thunderbird
Source: by performanceprobe.com
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Oil, SAE Viscosity Grade Recommendation; "...If you have a older engine, you can keep it going strong for years by increasing the oil you use to 20W 50. I have been running my engine with 5 quarts of 20W 50, 1 quart of Lukas Oil Stabilizer and a high quality filter for several years now all 4 seasons. That makes it a little stiff until it warms up when temperatures are in the teens, but that is easily solved by using a block heater to keep the oil warm..."
Source: by Seabronc (Rosie, Fred W) at Ford Bronco Zone Forums
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Oil, SAE Viscosity Recommendation TSB 98-8-16 for 89-96
Source: by miesk5 at FSB
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Remanufactured Engines & Transmissions - Dual Brand, Broncos & all Ford vehicles 35.29 MB pdf
Source: by fordinstallersupport.com
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Remanufactured Engines & Transmissions - Motorcraft® Brand, Broncos & all Ford vehicles 19.38 MB pdf; Halli wrote on 30 DEC 2010 that
For a Ford Reman 5.8l long block it is 2308.00 exchange. 2210.00 for a 5.0; These are Ford dealer prices in the Mid-South. Reman 5.0 = $1914.56; j. r. Nice wrote on 5 MAY 2012, Ford crate 5.0 H.O was about $1900. My local rebuild on my 5.8 was about $2300; radiolotek wrote on 19 May 2012, $2300. For a complete assembly (1995 5.8)
Source: by fordinstallersupport.com
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Repair Locations Grid & Coding, Bronco; used to pin-point location of a repair or component in a vehicle
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Repair Manual, Auto Repair Reference Center Repair Manual, Mostly Chilton; many local library's offer free online access for their members; just log-in w/your library Card # and password; incl. all Broncos, & many MAKES! 1951 to 2009; some years (85-96, I believe) include: FULL Technical Service Bulletins and Recalls, Labor Hours per repair (plug in appl info); Wiring Diagrams, Vacuum Diagrams (in DRIVEABILITY AND EMISSIONS CONTROLS Section), Specifications (torques, etc.) & Maintenance Intervals
Source: by arrc.epnet.com
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RTV Sealer Limited Shelf Life TSB 90-1-8 for 88-90 Bronco, Aerostar, Bronco II, Econoline, F-150, F-250, F-350, Ranger; 88-90 C Series, Cargo Series, F & B Series, L Series, etc.
Source: by Ford via performanceprobe.com
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Swap Fact Sheet
Source: by EPA
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Torque Specifications 87-96 (4.9, 50, 5.8, 7.3): part 1
Source: by Chilton via miesk5 at Ford Bronco Zone Forums
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Tuning for Performance & Economy, Chapter 9, from Ford Fuel Injection and Electronic Engine Control: How to Understand, Service and Modify, 1988-1993
Source: by Charles O. Probst via yunost.ru
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Vacuum Gauge Diagnosis
Source: by jerickweb.50webs.com
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Vacuum Gauge Diagnosis for Carbureted Engines
Source: by Craig U at classictruckshop.com
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Vacuum Leak Test On an idling engine using a mechanic's stethoscope w/ probe removed, or a ~3' garden hose section. READ MORE
Source: by miesk5 at FSB
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Vehicle Emission Control Information (VECI) Decal; Contains Vacuum Diagram & Calibration Parts List for 88 & UP. On-Line for Free at Ford. Click "Quick Guides" in left panel; Scroll to & CLICK VECI Labels "Provides Vehicle Emission Control Information (VECI) and a related calibration parts list." Enter applicable info (need to know your Calibration number (also called catch code) from your B-pillar sticker). Vacuum Diagram is the same as the one on the core support or hood or air filter cover. Suggest Right Clicking this Hot Link & Open in New Window
Source: by Ford motorcraftservice.com
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Vehicle Emission Control Information (VECI), PUK (49 States) Decal, PGP (Canada) Decal & Emission Calibration Number Label Overview, Location in a 93; "...Each vehicle is equipped with a decal (Figure 1) containing emission control data that applies specifically to that vehicle and engine. The specifications provided on the decal are critical to servicing emissions systems. In addition to the tune-up specifications and procedures, the emission decal shows a color-coded schematic of the engine vacuum system. The color coding on the schematic represents the actual color coding on the vacuum hoses. However, there will be instances where an individual hose color will not agree. The Emission Calibration Number Label (Figure 2) contains the engine calibration number and is located on the driver's side door or door post pillar.
Source: by thedieselstop.com
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Vibration Diagnosis & Terms
Source: by sandiegoenginebalancing.com
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