Jim's 1982 300 Six Bronco Original Restoration

Ah nevermind. I actually ended up pulling everything out. Time to clean the case and paint it!

Well, been there, done that, and now it is dirty.  

I actually powder coated the one for Big Blue, but then I took it offroading and it got dirty.  Still, it cleans up so nicely that I'd do it again.  

Looks great! Its interesting to see how different the t19 is.. if you plan to do a rebuild you will be replacing the bearings for the lower shaft anyways so it will have to come all the way appart. I would think a thorough cleaning before reassembly would be basically required. The easiest and probably best looking way to clean it would be to take it to an automotive machine shop to be tanked. I would have done tgat with mine but I decided to leave the reverse shaft and gear in place since there arent any servicable parts "down there" in the 435. Didnt want to "cook" that bearing.

You might even get "by the batch" pricing if you can find enough stuff to fill up the tank. Who knows. Bellhousing would be another good candidate

I didn't work on the truck today, but I did make some art...

I purchased an overhaul kit with all bearings, gaskets, and synchro rings. I also got a first gear. I understand I also need assembly grease.

One thing I cannot find is a new 44 tooth reverse gear. Does anyone know where I could acquire one?

Loving the art!

Does anyone have info on getting transmission gears repaired at a machine shop? Like the cost and quality of work? I still haven't found a replacement for my reverse gears and I feel like it could probably be fixed by a good machinist but that's way out of my wheelhouse.

I don't know anything about repairing gears.  But have you tried Midwest Transmissions?  They have always had the tranny parts I've needed.

I know this isnt an answer to the question, so sorry in advance.

In the only picture we have of the gear, it looks ok. Is there some kind of major flaw that isnt apparent in the photo? Personally, unless the gear is severely damaged with lots of broken/chipped teeth, cracks, etc, I would probably not worry about it. These transmissions went in trucks that weight twice what your bronco does, behind engines making twice the power and significantly more torque, and were often used for towing too. Its pretty overbuilt for a 3800 pound half ton that will never see 250ftlbs at the flywheel. Reverse is low speed, and you probably wont roll 2 miles in reverse in the next 2 decades.

I dont mean to be dismissive of your problem, I know that can be frustrating. Perhaps you could find a replacment gear from an otherwise unservicable junk yard tranny? Maybe someone in the tranny business ( like midwest) can find one?

I dont know who you tried for the parts but I have used https://www.thegearbox.org/home.html
for WC T5 parts for another project.
Dave ----

Rear axle is in, the truck sits on a brand new suspension finally. Took almost 3 months to get my third member from QuickPerformance and I'm disappointed it didn't come painted like it was shown in the image on their website. Oh well.



I managed to get a reverse gear on Finditparts. Some dude near me has a 80-86 tailgate he wants to swap for my 89 tailgate. It has a bunch of bullet holes so I'm not sure what's usable.

Next step is to drop the transmission, transfer case, and driveshafts. I'm just going to open and inspect the transfer case. Driveshafts I'm not sure whether to rebuild mine or buy new. I was going to make my own brake lines but I decided I could just work a few hours of OT and bite the cost of pre-bent stainless.

I found a way to get past CA emissions by registering the truck in South Dakota under an LLC in New Mexico. I doubt I would be able to get the emissions equipment working well enough to register it in California and I am thinking about doing a Holley Sniper 1100 single barrel throttle body fuel injection conversion way on down the road which is illegal here.

That axle looks good!  And I think I see Bilsteins in there.  

On the brake lines, my experience with Inline Tube was very poor.  Every bend was wrong and I had to correct them.  And they sent the wrong pieces several times, and claimed the problem is that there are so many different lines for a Ford.  Not true.

Anyway, I don't recommend buying from them.  But if you do be prepared to re-bend every piece and have them make a new part for the rear where the lines connect to the tee as they don't understand the size of fittings the Fords use.

Dang. Yeah the ones on Jeff's Bronco Graveyard are from Inline Tube and I assume the ones on LMC Truck are the same ones because they're about the same price. Are they the only manufacturer that makes em?

I have a bunch of copper-nickel alloy tubing at home, guess it's time to practice my double flares. I have equipment at work to do stainless with Swagelok-type fittings but that would be complete overkill...But cool nonetheless.

Unless going for a show truck and want the brake line to stand out I would not go SS.
The reason is SS is vary hard so unless you have the big dollar tool to flare SS that would be the first thing.

Also and the big one for me,because SS is hard you cant get the connections to seal right.
The flare crushes a little to make the seal and the SS will not crush.

I dont remember who I used for my 70 AMC Javelin but I found https://classictube.com/ with a Google search just dont know if they have anything for our trucks?
Dave ----

FuzzFace2 wrote

Unless going for a show truck and want the brake line to stand out I would not go SS.
The reason is SS is vary hard so unless you have the big dollar tool to flare SS that would be the first thing.

Also and the big one for me,because SS is hard you cant get the connections to seal right.
The flare crushes a little to make the seal and the SS will not crush.

I dont remember who I used for my 70 AMC Javelin but I found https://classictube.com/ with a Google search just dont know if they have anything for our trucks?
Dave ----

Yeah that's why I was spitballing about Swagelok fittings, impossible to screw up and holds several thousand psi. Flaring is obsolete, but not according to the DOT.

I checked that website you linked and they had some stuff for Bullnose F-series trucks. Nothing for Broncos

tcbaklash wrote

Yeah that's why I was spitballing about Swagelok fittings, impossible to screw up and holds several thousand psi. Flaring is obsolete, but not according to the DOT.

I checked that website you linked and they had some stuff for Bullnose F-series trucks. Nothing for Broncos

I would have to look up you Swagelok fittings but I was thinking the same thing about DOT and your fittings.

As for nothing for Bronco I would get a kit for the F-series truck (F150) in either short or long bed if looking for a full kit.
My reason is the Bronco is a F-series truck just a little shorter.
Everything up front (master / axle) and out back (axle) would be the same and the line along the frame rail would be different. That is what I found between my 2 81 F100 trucks - 1 SB other LB.
Dave ----

They dont have brake lines but they have fuel lines. I don't know the fuel tank location on a F-150 but I'm gonna assume it's not behind the rear axle like a Bronco. Otherwise they have a fuel pump to carb line for a straight six, which I'm gonna buy and report back to you guys.

F-Series trucks can have either a mid-ship tank on the driver's side or that plus an aft-axle tank like the Bronco.

tcbaklash wrote

They dont have brake lines but they have fuel lines. I don't know the fuel tank location on a F-150 but I'm gonna assume it's not behind the rear axle like a Bronco. Otherwise they have a fuel pump to carb line for a straight six, which I'm gonna buy and report back to you guys.

They dont have brake lines for the F trucks?
That is strange as I would think for given years they would be the same, 150 for all 150's 80-86 same with the 250 / 350.

Being the Bronco is a shorter pick up I figured the PU lines would work but if they dont make them for the PU guess you are SOL

As Gary said the PU's do come with a after axle tank

Dave ----

Trying to get my brake lines right. The Titan flaring tool I bought does a good job, but my cutting and filing and deburring can use some work. Here's some of my work before blowing out the debris with brake cleaner


If I can't use the F150 fuel lines then I will have to buy the appropriate sized Titan flare tool. I might just use the old ones and upgrade to high pressure lines when I get the Holley Sniper 1100.

Also I'm not sure how you guys bend your brake lines, but I zip tied the old lines to some tubing and bent the tubing exactly side-by-side. They look kind of funny to me when they're on the truck, I might re-do them OCD style in the future.


Driveshafts and transfer case are out.


Also got to use my new toy. I am still getting used to how it works. The head was much larger than I was hoping, so it doesn't fit everywhere a standard ratchet can.


Has anyone purchased the Bronco driveshafts from Jeff's Bronco Graveyard? I can't find anything on the u-joint sizes. Also, not gonna be rock crawling or anything, but they are really cheap compared to most other ones I find online, just want to make sure I'm getting something that's straight and balanced.

I'm also gonna have to post some pictures of the transfer case shifter linkage that came out of my truck so I can pick all your brains about needing a "standard" shifter linkage or converting the one I have. Since the factory transmission is a SROD, things are a bit different down there.