89 Bronco 460/ZF swap

Got the BBK dual 61mm throttle body




Old was 2.2ish per bore



New is 2.4ish



Bolted onto the upper

Trying to get the pully off of the sag pump, my new puller broke the little flange off od the pulley, So I got pissed off, cut the pully in half with a cutoff wheel, and used the same wheel to remove the pulley.



Set the bracket onto the engine to measure bolt lengths




Since my truck already has a 2 guage pod in it, I needed something to replace the tranny temp guage, as my ZF5 won't be needing that so I picked up this



I also picked up this



And a test fit on the fuel pressure regulator

Headers!



Cats investigating



Set them on to see how they fit...









Mr Cassius Clay is not impressed

Cool dog. We got a boxer last summer.

cool build, nice work!

I dont have enough pedals inside the truck to run this new motor/tranny setup so some teardown had to happen..



Gear indicator has to go..



Ouch.



Stock pedals out and the blockoff plate for the clutch mc



Comparison



New pedal pads

This was my brackets when I got them back from sandblast, I had already modified the alt bracket to remove the smog pump, but the van ps bracket was still in need of work



I had them cut back the mounting locations because the longest ARP 12 point 7/16 bolt is 5"



Here is the alt bracket with the 3G ready to go




Did some hand grinding on the ps bracket to make it look better




Here it is after I had it re-sandblasted




Started playing with the wiring...forgot how much there was. Probably wont see much of this engine anyway

Got all my stuff lined up finally for the remote oil filter

Engine side



Filter mount

Having problems with the dipstick, the one that came with the oilpan is in the way of the headers..I bent it a little and it got bound up.


Got a lokar one lokar one and it does not fit.

Some pics. the pan...



The dipstick comparison



Getting irritated. Should have got the milodon oilpan, at least it came with a dipstick that would have worked.

I used a factory style dipstick on my truck with no problems. I did have to do a little creative massaging to get it around the headers, but take your time and it will work.

Took the dipstick apart and used my drill as a lathe, and then used a grinder with a cutoff wheel to make a groove for the clip and reduced diameter to fit the hole in the pan.







Set it in to see how it looks

Installed EGR blockoff for now, I really want to get this thing together.




used a wall anchor in the hole in the valvecover to tie down the wire looms..took me a bit to figure out how I was going to do this..

New injectors installed





Getting closer





I hate putting together braided lines btw.



I measured for belts, the ac belt is the same as stock, the alt belt is 2" shorter.

I am going to try to get the frame standoffs swapped out in the bronco so I can get this thing put in there soon.

Finally a day without rain...

Had to remove the smallblock frame standoffs to be able to use factory 460 mounts..

this is the smallblock mounts.




Cleaned up and painted the crossmember



460 mounts are marked for it, I thought that was cool




Some fresh paint will make these look nice

Got the gatorback belts on to check routing, looks like they will work



Factory 2 peice motor mounts are on there





Bracket for the coil, Just need one bolt down on the header then this is good to go



This thing is ready to go in. Hoping for sunday.

Big progress today, but still a long way to go.

Tranny cleaned up..



Dad in place to install motor mount standoffs to the frame



Like this




Pulled the tires so we dont have to lift the motor as high



Motor on the chains



New clutch installed (found 2 bolts close enough)



My dad



Last shot before it goes in



Pulled the hood, now here it goes

Motor dropped right in



Pulled the seats and console so I can pull the access cover



So the ZF will fit



Tranny is strapped in right now, I have decided to make a new mount. Wouldnt be an issue to just slide the stock one back, but the SAS and cage arms make this an issue.



More lookin at the motor after we put the hood back on





Nice looking in there and not seeing the ground



Big tires back on..(been off since September)



Lots of work still to do, but this was a big day for the Street Truck.

looking good! bet you can hardly wait!

Street truck now has 3 pedals.



See the small mc next to the booster.

Semi irritating day working on the bronco..

Mini starter that I ordered from broncograveyard does not fit. I am not suprised for some reason.

Passenger side header went on, but it is WAY tight.








Just cause pic



Set the injectors on



Drivers side header does not fit...at least till I figure out where to move the brake T. It is 100% in the way.

Any updates on this project? I really enjoyed reading about the buildup, just wondering how it worked out and ran?

-Michael

8 years later i figure out that i never finished this story...i'll see what I can put together