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

[KLAKEBRONCO]

From info I've gathered at FSB, the timing bump give a decent increase in MPG.
From there I'd look at changing the Y-pipe. Again everyone who does it states an increase in MPG, and power.

Like in the post above, the diesel swap IMO just doesn't make sense. So may as well optimize the gas V8.

 

[KLAKEBRONCO]

One other thing to add....
Look under your truck and look at how huge, and how far down the gas tank hangs.
I swapped my stock 33 gallon tank for a 19gallon tank. With the way I have it set up the very front of the tank hangs down a couple inches, and the rest is tucked up to the frame.

If you are stock suspension, and stick to 31" tires, 20mpg is a very real possibility. That's a 380 mile range, which IMO is plenty. If not a 10 gallon jerry can brings that up to 580 miles.

The other thing I'm planning to do is buy a T-case clocking ring from Great Lake offroad, and clock the T-case level, and build a new skid.
The T-case and it's skid, and the stock tank are the two things that hang the lowest on these things.

 

[JohnMcD348]

Klake, I've got the 300 in my Bronco. '92 EFI 300 with the M5OD and manual Transfer case. I'll keep my 33gal tank and probably keep the 3.08 gears upgrade to a 3.55/73 or 7 whatever the next higher is and 31" tires for my last serious mod. When I change the gearing I will definitely convert it over to an LSD unit also. Once I get the engine running at top performance I'll start working on modding the interior for gear storage and such. I/m really not sure if a YPipe mod would be that beneficial for me. Being an EFI, I've already got the high flow headers. I do suspect I probably have a few pin holes in the exhaust and would like to get a newer freer flowing but quiet exhaust including Catalytic Converter.

One question, what is a T-Case Clocking ring? I've never read anything about them.

 

[KLAKEBRONCO]

One question, what is a T-Case Clocking ring? I've never read anything about them.

It is a thin steel plate that bolts to the back of the transmission, and then the T-case bolts to it. It has multiple holes in the plate that allows you to rotate the transfer case. This will allow you to rotate it so it doesn't hang below the frame.

 

[JohnMcD348]

Oh OK, interesting. I really hadn't noticed there being much in the way to snag or hang up under the Bronco but I guess I just never really looked that hard before.

 

[KLAKEBRONCO]

Oh OK, interesting. I really hadn't noticed there being much in the way to snag or hang up under the Bronco but I guess I just never really looked that hard before.

Ya, that T-case skid plate hangs down several inches. The gas tank does too. That's why I swapped to the truck tank.
The exhaust hangs below the frame too.

 

[JohnMcD348]

I guess my real question is whether clearance is that much of an issue with our Broncos. Even factory stock, they are pretty good. Unless you're planning on moving through heavy rock terrain or over fallen wooded areas.

 

[KLAKEBRONCO]

I guess my real question is whether clearance is that much of an issue with our Broncos. Even factory stock, they are pretty good. Unless you're planning on moving through heavy rock terrain or over fallen wooded areas.

For me it is because I am going to go to some of the local offroad parks.....And it isn't lifted, nor do I want it to be. So anything I can do to gain clearance, without lifting is something I'm either doing, or looking into.

 

[JohnMcD348]

For me it is because I am going to go to some of the local offroad parks.....And it isn't lifted, nor do I want it to be. So anything I can do to gain clearance, without lifting is something I'm either doing, or looking into.

I've been thinking about that alot. I really don't need or have a need for a lift either on my vehicles but I have been considering getting a 2-3" suspension system for no other reason than to update and upgrade the nearly 20 year old suspension that's on the vehicle. It's not extreme, won't put a strain on the body or chassis and overall isn't that noticeable. It would allow for larger tires but even without them wouldn't be all that bad.

 

[kjp1969]

For me it is because I am going to go to some of the local offroad parks.....And it isn't lifted, nor do I want it to be. So anything I can do to gain clearance, without lifting is something I'm either doing, or looking into.

Does clocking the t-case affect the fluid levels? In stock position there is a fill plug that you top up to overflow with oil. What happens to the overflow level when you clock it?

 

[JohnMcD348]

I don't think it would effect it overall. You would still need a pump to change the fluid in it. The transfer case and transmission in mine uses ATF type fluid instead of regular gear oil as in many older transmissions. I don't remember off the top of my head what unit and year Klake's Bronco is but if it's close to mine, ti wouldn't be an issue.

 

[thecarman]

Does clocking the t-case affect the fluid levels? In stock position there is a fill plug that you top up to overflow with oil. What happens to the overflow level when you clock it?

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.

 

[Greggk]

460 big block, 4" lift with 33's, arb air lockers front and rear, winch with proper bumper, etc etc.

a 460 big block in a bronco is so much FUN!!! trust me i know. i got 400hp and 500 pound feet of torque with mine.

 

[JohnMcD348]

Wow. I'd hate to have your gas bill. Do you drive it regularly or is it strictly a trail runner?

 

[Greggk]

i recently sold it, but it was a daily driver and i got better fuel mileage with the 460 then i did with the factory 302. I averaged 13mpg with the 460. As long as you drive conservative it isnt bad.