So the brake system is now complete.
Were now rocking a master cylinder & brake booster for a 1996 F350, to match the axles
Brakes are plumbed to the front axle:
...and thanks to a spool of tubing...
The rear half of the brakes are completely replumbed as well!
This i thought was interesting. Rough Country extended stainless brake line for a bronco with 4-6" of lift, next to the OEM F350 brake hose:
The stainless line is only 1" longer than the OEM hose, which means for most mildly lifted trucks, the OEM F350 hose is just fine. I already had the extended line though, so i used it.
So with the brake lines done, theres not much left to do under the truck, so its time to move under the hood!
Decided to get the tracbar for the Better Half done this week:
Mocking it up, the bar needs to be roughly here, to match the draglink angle
Took some time with the upper mount, as i wanted something that would bolt up in place of the original TTB pivot, so i didnt have to drill any more holes in the frame:
The lower mount on the axle
Im not in love with the lower mount, but i think itll do the job ok. I would have preferred to put the mount closer to the knuckle to get the bar longer but im pretty sure it would have hit the springs when the pass side drooped out, so i had to compromise. Im not building a hardcore long-travel rock crawler anyways, so i think itll be ok as is.
Threw on an old diff cover i had, RuffStuff maybe? Dont remember anymore. Lube locker gasket as i have them on multiple trucks now with no leaks:
Pretty sure thats the cover i used to run on the D70 in the rear of the 88 as the lower edge is ground down pretty good.
Got that Carolina Squat yo!
Pretty sure its sitting at 4" of lift. i was surprised at how good the the drag link angle looks considering its stock F350 steering with a stock bronco pitman arm. I might try to get my hands on an F350 arm since theyve got ~1" more drop just to level it out a bit more, but i dont think i need to spring for a proper drop pitman arm. I gotta root around in the garage and see what i have. I have parts to build a tracbar but thats coming later. Tires are a junk set of 305/70R16 on stock Ford wheels, because its what i have for rollers. We have a set of 315/70R17 we bought on CL for cheap in the garage ready to go, just dont have a set of wheels for it yet, that one is up to the wife since its her truck.
I have a set of F350 shock towers in the garage that will go on the front eventually. For now my goal is to get the rear lifted and the 10.25 in so i can pause, clean up, take a trip to the scrap yard, and then roll this thing into the garage for the rest of the rebuild. It hasnt run in years so its gonna need a major tuneup at the very least (it also needs a gas tank, fuel pump & skid plate) and who knows if the transmission even shifts. I want to open up the tcase to inspect the pump, the exhaust is rotted out and falling apart.....the list goes on.
Cant leave it like this forever!
Scored a set of leaf springs out of an Excursion pretty cheap a while back, so we're going to use the front set!
the Excursion guys hate these leafs, they think theyre too soft and usually switch to V-codes out of the Superdutys. So hopefully these will be just right for a bronco!
These things are a bit rough though. All the anti-friction pads are shot, and the center pins look rough, so its all getting replaced
New anti-friction material from Speedway, and a set of new pads from Dorman:
Wire wheel, paint, new pads, bushings, center pins and done!
We're using the 2wd version of a 2" shackle reversal for a 85-91 F250/F350 from Sky's Offroad Design, along with quite a few other parts from them that you'll see show up as this project moves along
Sky's low clearance shackle hangars
...and the front hangar installed! The 2wd hangar fits right up on the bronco's frame like it was made for it. The 2wd version comes with plates for the inside of the frame horns to box them up a bit so its nice and stiff once its all bolted together.
...and the leafs installed!
Next up: getting that D60 installed!
This rusty mess needs to go
...yup, thats better:
coil buckets removed:
pivot and radius arm brackets are next on the list
And so, with the frame stripped of all the TTB parts, i want to deal with all this rust and scale
needle scaled, wire wheeled.....
Looks a million times better now! Finally, its time to start bolting parts back on!
Absolutely scored on this deal. Back over the winter i found a 97 Ford D60 still in a truck in a junkyard. Got it pulled and dropped right into the back of my truck for $250! Wasnt easy getting it back out of the truck though....
So lets get this thing cleaned up a bit, shall we?
You could tell it came from a plow truck. Everything rusty, but also new seals and clean grease everywhere
My little helper getting in there and scraping grease and grime off it
Cutting off the sway bar bracketry, along with the retainer for the ubolts and the tracbar
Housing needle-scaled and wire wheeled
...and getting a fresh coat of paint!
Diff out, shaft & pinion seals changed
...and the final reassembly