Would like pointers/input on converting a Bronco to Expedition status

[KLAKEBRONCO]

Yes - clocking moves the fill plug. You need to draw a level line across the back of the T-case at the height of the fill plug stock, then draw another level line once you have clocked it. Think about what your new (clocked) fluid level might leave un-lubricated vs. the original fill line, and figure out how much you need to fill now that it's clocked. You may need to fill through a different bolt on the T-case, or through the breather tube. If there is a convenient bolt at around the right height on the case, then you have a good place to fill and to check fluid level. If not, you can make a "sight glass" by putting some 90-degree fittings in a higher bolt and in a lower bolt and attaching a piece of clear tubing between them. Then you can fill from a higher bolt, and see your fill level in this tube.

To answer the earlier question mine is a 1356 T-case. So it uses ATF also.

Those are good tips to maintain a way to keep it full.
Other than the appropriate level I don't think there would be any problem at all in clocking the case. With the lower viscosity oil (vs the cases using gear oil) there should be no problems keeping everything well lubed.

FWIW I haven't clocked the stock case yet on my Bronco.

 

[kjp1969]

Yes - clocking moves the fill plug. You need to draw a level line across the back of the T-case at the height of the fill plug stock, then draw another level line once you have clocked it. Think about what your new (clocked) fluid level might leave un-lubricated vs. the original fill line, and figure out how much you need to fill now that it's clocked. You may need to fill through a different bolt on the T-case, or through the breather tube. If there is a convenient bolt at around the right height on the case, then you have a good place to fill and to check fluid level. If not, you can make a "sight glass" by putting some 90-degree fittings in a higher bolt and in a lower bolt and attaching a piece of clear tubing between them. Then you can fill from a higher bolt, and see your fill level in this tube.

I suppose you could drive 2 wheels up on the curb until the t-case was at it original orientation, then check and fill.

 

[78Bronco]

The 13-56 t-case has a pump in it. A very simple unit that is prone to failing because the little cast tab inside the magnesium case breaks off and the pump spins. No more oiling. It force feeds oil down the main shaft to bearings and planetary drive. The oil level is important in the planetary gear cases which is why they have a small pump. The transfer cases with a slip yoke are alright if keeping the lift low. Improving the skid plate and changing out the gas tank to something lower profile is a good idea too. If you have a receiver hitch those things are land anchors think about a new rear bumper to help protect the back with proper tow points. Did I mention proper tow points.

Remember that if you install leveling springs and raise the front ride height you will need longer shocks so you aren't jamming the valve into the shock's body at full droop. With longer shocks you might aswell use F250 shock towers and then install longer brake lines to. 33's is a good size of tire. TTB front ends can be the best of both worlds, indepedent and similar to a live axle. Air bags are great for leveling the truck when it's loaded up.

If you are looking for parts I have a Dana Powerlok carrier that will fit your front diff that has brand new clutch packs. It has to be one of the best limited slips at 70-90% lock up but not harsh like a locker. Fully rebuildable as well with two different clutch types, standard and aggressive. I also have brand new gears and master install kit to outfit a high pinion dana 44. I am pretty sure they are 3.73:1 yukon with timken bearings reverse cut. Let me know if it interests you they are some spares I probably won't need as I have 4.10's in my '78.

My plans for my bronco is to swap in an inline 6 EFI with an 11-inch luk clutch in place of the carb'd 351M but first the extended radius arms need to be finished. Should be able to finish it soon. I'm keeping my eyes pealed for some newer bronco xlt seats and console. A roll bar is a good idea to protect passengers and mount a fire extinguisher to it. Then plan some storage system that suits the items that you want to carry. It can be quite dangerous to drive around with loose heavy objects in the cab with you. A lady here died from her laptop sitting on the back seat when she was struck by another car from behind.

:smiley_drive:

 

[Cody1771]

FYI guys the 460 BBF arnt to bad on fuel.... well when your talking about big V8's at least, i know a BBF 460 will get the same milage as my 400SBC, 10-12MPG 14 if your really good on it, remember with tons of power it only takes a touch of the throttle to maintain speed

 

[KLAKEBRONCO]

The 13-56 t-case has a pump in it. A very simple unit that is prone to failing because the little cast tab inside the magnesium case breaks off and the pump spins. No more oiling. It force feeds oil down the main shaft to bearings and planetary drive. The oil level is important in the planetary gear cases which is why they have a small pump. The transfer cases with a slip yoke are alright if keeping the lift low. Improving the skid plate and changing out the gas tank to something lower profile is a good idea too. If you have a receiver hitch those things are land anchors think about a new rear bumper to help protect the back with proper tow points. Did I mention proper tow points.

Remember that if you install leveling springs and raise the front ride height you will need longer shocks so you aren't jamming the valve into the shock's body at full droop. With longer shocks you might aswell use F250 shock towers and then install longer brake lines to. 33's is a good size of tire. TTB front ends can be the best of both worlds, indepedent and similar to a live axle. Air bags are great for leveling the truck when it's loaded up.

If you are looking for parts I have a Dana Powerlok carrier that will fit your front diff that has brand new clutch packs. It has to be one of the best limited slips at 70-90% lock up but not harsh like a locker. Fully rebuildable as well with two different clutch types, standard and aggressive. I also have brand new gears and master install kit to outfit a high pinion dana 44. I am pretty sure they are 3.73:1 yukon with timken bearings reverse cut. Let me know if it interests you they are some spares I probably won't need as I have 4.10's in my '78.

My plans for my bronco is to swap in an inline 6 EFI with an 11-inch luk clutch in place of the carb'd 351M but first the extended radius arms need to be finished. Should be able to finish it soon. I'm keeping my eyes pealed for some newer bronco xlt seats and console. A roll bar is a good idea to protect passengers and mount a fire extinguisher to it. Then plan some storage system that suits the items that you want to carry. It can be quite dangerous to drive around with loose heavy objects in the cab with you. A lady here died from her laptop sitting on the back seat when she was struck by another car from behind.

:smiley_drive:

Good info on the T-case. I've never had one apart, but I've heard you can sheet metal screw through the pump which will hold it in place so it doesn't fall off....I don't know what that means honestly, just something I read about that case.

It's funny the TTB trucks have the big coil bucket with shock mount built in, but I think I'm going to do just what you said. Replace the bucket with one from a 78-79 and use an F-250 shock mount. (got any coil buckets, or lower spring buckets/retainers for your gen Bronco?)

Building a rear storage drawer setup is on my to do list. Hopefully be done before my next trip in late Oct.

 

[78Bronco]

Good info on the T-case. I've never had one apart, but I've heard you can sheet metal screw through the pump which will hold it in place so it doesn't fall off....I don't know what that means honestly, just something I read about that case.

It's funny the TTB trucks have the big coil bucket with shock mount built in, but I think I'm going to do just what you said. Replace the bucket with one from a 78-79 and use an F-250 shock mount. (got any coil buckets, or lower spring buckets/retainers for your gen Bronco?)

Building a rear storage drawer setup is on my to do list. Hopefully be done before my next trip in late Oct.

That's right the fix is to use a screw to ensure it doesn't spin. If a 13-56 is going to fail it's an oiling issue 99% of the time.

I got lots of parts kicking about for mine

 

[JohnMcD348]

What's a decent inverter that's not terribly expensive? I'm working on doing a dual battery conversion and will be adding a second battery install also in the near future. I want to install an inverter in the rear cargo area to provide power to small power tools and such. I would probably keep a few of my Craftsman C3 tools loaded when out tripping(Drill, saw, Impact driver, Light, etc). I'll keep the smart charger plugged in. I don't really have any major high power needs but would like to have the ability in an emergency even if on a limited basis.

 

[KLAKEBRONCO]

What's a decent inverter that's not terribly expensive? I'm working on doing a dual battery conversion and will be adding a second battery install also in the near future. I want to install an inverter in the rear cargo area to provide power to small power tools and such. I would probably keep a few of my Craftsman C3 tools loaded when out tripping(Drill, saw, Impact driver, Light, etc). I'll keep the smart charger plugged in. I don't really have any major high power needs but would like to have the ability in an emergency even if on a limited basis.

The best way to go is to find a guy parting out an older travel trailer...

Beyond that, despite what some say, just buy a walmart special. I've had a 300 or 500 watt, from an autoparts store for YEARS now, and it has ran everything from jig saws, TV's, phone chargers, DVD players, etc, etc.

When I hardwire an inverter I'm going for a 1,000 watt inverter from Harbor Freight.

 

[JohnMcD348]

I have a couple of older Campbell Hausfeld Compressor/Jumpstarter units that have bad batteries in them and was thinking of scrapping them and using the 450Watt inverters to mount into the Bronco but also getting something like a 1000watt unit for something bigger, just in case. Who knows, maybe I'd need to plug in the Plasma 54" HDTV and Satellite to catch the game one night in the middle of nowhere.:victory:

I looked at the HF units and they are all Modified Sine wave units. They're fine if all you're going use it for is power tools but if you're going to possibly use it for anything electronic, you'd be better off in the long term to get a Pure Sine Wave unit. The power is "cleaner" and won't ruin the electronics. I may get one of the 30-450W Pure units in case the wife wants to run her laptop and have a 1000W unit for any possible heavy tools or something else like that.

 

[KLAKEBRONCO]

I have a couple of older Campbell Hausfeld Compressor/Jumpstarter units that have bad batteries in them and was thinking of scrapping them and using the 450Watt inverters to mount into the Bronco but also getting something like a 1000watt unit for something bigger, just in case. Who knows, maybe I'd need to plug in the Plasma 54" HDTV and Satellite to catch the game one night in the middle of nowhere.:victory:

I looked at the HF units and they are all Modified Sine wave units. They're fine if all you're going use it for is power tools but if you're going to possibly use it for anything electronic, you'd be better off in the long term to get a Pure Sine Wave unit. The power is "cleaner" and won't ruin the electronics. I may get one of the 30-450W Pure units in case the wife wants to run her laptop and have a 1000W unit for any possible heavy tools or something else like that.

Just buy a breakered power strip

 

[JohnMcD348]

My plan is to build new rear interior panels to replace the cheap flimsy cardboard ones in my Bronco and incorporate power outlets into them along with a couple of storage compartments.

 

[KLAKEBRONCO]

My plan is to build new rear interior panels to replace the cheap flimsy cardboard ones in my Bronco and incorporate power outlets into them along with a couple of storage compartments.

I was going to do the same. I built and installed one side, and haven't done the other because I wasn't sure exactly what I wanted.
Since then, I've decided to get a trailer, and am going to pick it up today. That will probably change what I do on the inside of the Bronco.

One thing I am going to do is build a platform with storage about 10" up from the floor. I want to keep the roof on, and you can't exactly haul anything tall back there anyway, so the 10" platform won't hurt a thing in that regard. It will give lots of storage though.

I'd like to see your panels so post up some progress when you get to it.