Build Thread - 69 Bronco

[bulletpruf]

Have been working on my '72 Javelin 24 Hours of Lemons build, but will get back on the Bronco soon. I have two original Bronco 3.03 3 speed manual transmissions that I brought home from the shop. I'll rebuild one of those in the near future. Once that's done, I'll get started on the budget friendly 302 rebuild - just a stock'ish bottom end with some GT40P heads.

 

[PhantomEB]

mines hitting Dirt and Rocks this spring. Down to the little things and making it look better for car shows this year too.

 

[bulletpruf]

mines hitting Dirt and Rocks this spring. Down to the little things and making it look better for car shows this year too.

Looking good! Is it running and driving now?

 

[PhantomEB]

Close to, back in the garage for fluid top ups/leak fixes, and little details Before it hits dirt and rocks this spring. Getting close to weekly drives to work and back.

 

[bulletpruf]

Close to, back in the garage for fluid top ups/leak fixes, and little details Before it hits dirt and rocks this spring. Getting close to weekly drives to work and back.

That's awesome. How long has it been since it was running and driving?

 

[PhantomEB]

It runs as is, I just need to bleed brakes and weld up the angle bracket for my shifter then I think I good to go for around town. Need to hook up the triple stick as well before skidplate gets bolted up which she’s good for the trails. Lots of details like lights for this and that plus a rack for over the batteries and fuel cell are on the list.

 

[bulletpruf]

Working the 3 speed RAT transmission and it's been fun. The Bronco trans is slightly different than the passenger car trans, there are no YouTube videos of a Bronco trans rebuild, and the Shop Manual is not a model of clarity. But I got it apart.



I disassembled the cluster gear after I took this picture.



Rebuild kit from USA Standard Gear has plastic thrust washers. You've got to be kidding me. I am going to reuse the thrust washers for the counter gear; they're very nice. For the reverse idler, I found some NOS ones.





Now I need to find or make a dummy shaft for the counter gear shaft - .865" x 5.070". If I had a parts trans, I could just cut one down, but I don't have a parts transmission.

While I'm waiting on that, I'll work on reassembly. Will try to get the cluster gear reassembled before I start work today.

 

[WoodsTruck]

What kind of shape are the syncros in?
Mine shifted very fast but the main bearings started having a ton of slop in them. It would pop out of 3rd when going over a hill at highway speed going from power to coast. Had it gone through with another box and swapped parts (poor college student at the time) and it held in 3rd, but would pop out of 1st instead. Not quite the ideal trade off going down the driveway at my folks' place.

 

[bulletpruf]

What kind of shape are the syncros in?
Mine shifted very fast but the main bearings started having a ton of slop in them. It would pop out of 3rd when going over a hill at highway speed going from power to coast. Had it gone through with another box and swapped parts (poor college student at the time) and it held in 3rd, but would pop out of 1st instead. Not quite the ideal trade off going down the driveway at my folks' place.

Synchros and gears are actually nice. I’m replacing the synchros but I think it would have been fine if I reused the original ones.

 

[bulletpruf]

Cluster gear is together. That was fairly simple and didn't require a press.

Input and counter gear are loaded with needle bearings - 25 on each side for the cluster gear and 15 for the input.

Seal is installed in bearing retainer.

O-rings installed on shift arms.

 

[PhantomEB]

Funny I been having dreams of a second EB that I used as a street terror yet was the truck I used for highway trips….no roof at all….