A Big Step in the '21 Badlands Build

brnc_o_vrlndr

Nov 27, 2023

December 10th marks the 2nd anniversary of owning my 2021 Ford Bronco Badlands non-Sasquatch 4-door manual and it has been the best two years I have had with an offroad vehicle in my life! I love everything about this Bronco, but I knew from day one that I could not, and would not, leave well-enough alone. This post is not meant to be a full build documentation, as that would cause most people to check out well before the end, but it is meant to serve as an update to what is about to happen to the Bronco, and I cannot wait to try it out on the trails.

This past Friday, Black Friday, I installed 37" BFG KO2s, a decision I had weighed many times. "Will they make the front drivetrain too weak? Could I tolerate the loss of the manual transmission's extremely low crawl ratio (effective ratio after tire size is considered) going from 33s, 35s, and now 37s? Am I ready to start cutting things to make the tires fit, not only driving down the road, but when fully flexed on the trail? I ultimately decided that 37s was what I always wanted to add, so I will just put them on and figure out the rest as I go. So that is what I did. I stuck with the KO2s, as that is the only tire that has been installed on the Bronco from the factory 33s, the outgoing "35s", and now the 37s. I love the tires and have had no issues with them in almost 60,000 miles.

This week, to help strengthen the front end and maintain the awesome low speed crawling, I will be dropping the Bronco off at the local offroad shop to have the factory 4.70:1 ring and pinions swapped out for Yukon Gears 5.38:1 ring and pinions and replace the factory differential extension tube with BroncBuster's Differential Tube (an absolute monster compared to the OEM tube and another billet piece of art). After all is said and done, I will have the alignment done, for about the fifth time since owning the Bronco. To keep things from slipping, again, while offroading, I will also be adding the BDS Suspension Alignment Cam Lockout Plates, purchased through the Bronco Nation Parts store.

I quickly learned, even with my 1.5" wheel spacers (behind optional Badlands beadlock-capable wheels) and sketchy mix of suspension lift (perch collars and spacers), I ran out of space quickly when steering to full lock in either direction. To get by for now, I took out the Hackzall and cut an angle off the rear crash bar mounts. Also purchased from the Bronco Nation Parts Store, I ordered the JKS Max Tire Clearance Kit to replace the sloppy looking cuts I performed to make room for the new shoes.

I cannot wait to report back how the combination of 37" tires and new gear ratios performs!

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

ToxawayMTN, Darrel

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Nov 27, 2023

Wow, excited for you, Casey! I feel like you'll put it to the test well, too.

~~2021 Oxford White 2-door non-Sas Mid package 2.7L/10-speed Badlands with MIC top~~
2021 Carbonized Gray 2-door Sas High package 2.7L/10-speed Badlands with MIC top
Keeping the Jeeps: ~~stock '89 XJ and~~ 3.5" lifted '00 XJ on 31s and '89 MJ

Darrel, Chief Ron

Nov 27, 2023

Laura
Wow, excited for you, Casey! I feel like you'll put it to the test well, too.

Thanks, Laura. I know of at least one good test next year. Hoping to have the kinks worked out before then.

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Darrel, Chief Ron

Nov 27, 2023

Wow some nice mods coming. Post some pics when you get all this added.

looks like you are rocking the colorless BN badge too, or is it the white one.

Bronco Nation 1100. Everglades, Desert Sand
Res: 7/30/20 ordered 1/22/21 reorder 10/15/21 changed to Everglades 3/9/22 schedule 8/29/22 bumped to 9/5; 9/7/22 blend, 9/9 Mods, 9/26/22 completed, 10/7 shipped, 11/3/22 delivery

Darrel, Chief Ron

Nov 27, 2023

Jakob1972
Wow some nice mods coming. Post some pics when you get all this added.

looks like you are rocking the colorless BN badge too, or is it the white one.

Will do!

Yes, it is the white one. I have the black one in a box still.

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Darrel, Jakob1972

Nov 28, 2023

That's continuing to be a great build!! Can't wait to see it soon!!

And I'm over here contemplating perch collars for my Bronco 🤦‍♂️... lol..

(In my defense, I waited for BF & CM sales.... and I didn't find any discounted Perch Collars)

2023 Wildtrak, Iconic Silver, Hard top, ordered 10/5, built 12/13, delivered 1/18

Darrel, Jakob1972

Nov 28, 2023

Mikes2021Bronco
That's continuing to be a great build!! Can't wait to see it soon!!

And I'm over here contemplating perch collars for my Bronco 🤦‍♂️... lol..

(In my defense, I waited for BF & CM sales.... and I didn't find any discounted Perch Collars)

I believe Broncbuster has perch collars on sale. Put them in the cart to see discount.
Not sure if they are what you are looking for or not but take a look.

2022 Bronco Badlands, 4D, Hot Pepper Red, 2.7, Squatch, Lux, and MIC.
7/13/2020 10:04pm reservation. Blend 6/16/2022 Delivered 6/26/2022.
Dealership - Stephen's Auto Center.

Chief Ron, Mikes2021Bronco

Nov 28, 2023

Mikes2021Bronco
That's continuing to be a great build!! Can't wait to see it soon!!

And I'm over here contemplating perch collars for my Bronco 🤦‍♂️... lol..

(In my defense, I waited for BF & CM sales.... and I didn't find any discounted Perch Collars)

They are great by themselves, but I added 1.5” spacers as well. My upper control arms make A LOT of contact with the coils at full droop.

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Chief Ron, Mikes2021Bronco

Nov 28, 2023

Deano Bronc
I believe Broncbuster has perch collars on sale. Put them in the cart to see discount.
Not sure if they are what you are looking for or not but take a look.

I have the HOSS 3.0, and maybe 3 companies have did the R&D for those. I assume due to low demand vs 2.0. I'll look again, to make sure he hasn't slipped into the game of 3.0.. Thank you!!!

2023 Wildtrak, Iconic Silver, Hard top, ordered 10/5, built 12/13, delivered 1/18

Chief Ron, Deano Bronc

Nov 28, 2023

brnc_o_vrlndr
They are great by themselves, but I added 1.5” spacers as well. My upper control arms make A LOT of contact with the coils at full droop.

One fix cause 2 problems... it never ends!! Lol...

I hate to kill the somewhat better ride of the Fox shocks.. also I hate the nose heavy look. So perch collars are on the list of must have during this winter.

2023 Wildtrak, Iconic Silver, Hard top, ordered 10/5, built 12/13, delivered 1/18

Chief Ron, Deano Bronc

Nov 30, 2023

#10

Well, not a great first day. The shop called and one of the rear axles is already stuck (just under 60k miles and 2 years on the road). They are trying their best to get it out cleanly, as it also seems there may be supply issues with rear axle bearings, seals, and/or tone rings if they are damaged in the process of removal.

Here’s hoping tomorrow brings good news.

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Deano Bronc, Darrel

Dec 02, 2023

#11

brnc_o_vrlndr
Well, not a great first day. The shop called and one of the rear axles is already stuck (just under 60k miles and 2 years on the road). They are trying their best to get it out cleanly, as it also seems there may be supply issues with rear axle bearings, seals, and/or tone rings if they are damaged in the process of removal.

Here’s hoping tomorrow brings good news.

Any GOOD updates on the axle situation?

2023 Wildtrak, Iconic Silver, Hard top, ordered 10/5, built 12/13, delivered 1/18

Dec 02, 2023

#12

Mikes2021Bronco
Any GOOD updates on the axle situation?

Unfortunately, no. It is still up on the rack and the right rear axle will still not come out. The shop has pulled 50 times every hour with a slide hammer and they “think” the outer seal has moved. They have also been soaking it with penetrating oil each time.

Getting replacement parts is still an issue, as well. I am still hoping the kit I found on accessories.ford.com will ship and solve our parts problem. No updates on the order process yet, though.

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Deano Bronc, the poacher

Dec 02, 2023

#13

brnc_o_vrlndr
Hey Casey,

Really appreciate this post, as like you, I too have been debating whether to go 37"s or not. Posts like yours are leaning me in the direction of 37's, but I will wait and see as to your finished tests before finally committing.
A question for you, "are you still running the perch collars and spacer? Curious as to what size perch collar and spacer you are presently running to allow for the 37's.
Good luck with that damn sticky axle...

brnc_o_vrlndr

Dec 03, 2023

#14

the poacher
Really appreciate this post, as like you, I too have been debating whether to go 37"s or not. Posts like yours are leaning me in the direction of 37's, but I will wait and see as to your finished tests before finally committing.
A question for you, "are you still running the perch collars and spacer? Curious as to what size perch collar and spacer you are presently running to allow for the 37's.
Good luck with that damn sticky axle...

Thanks! We'll get there, hopefully sooner rather than later. Until I can afford an actual suspension system, I am still running the 1.25" perch collars front and rear, as well as a 1.5" top spacer front and rear. I have not had the 37s on a trail yet to see if that is enough lift. It should also be noted that I have 1.5" wheel spacers on the optional Badlands wheels.

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Deano Bronc, BuckYeah

Dec 03, 2023

#15

brnc_o_vrlndr
Thanks! We'll get there, hopefully sooner rather than later. Until I can afford an actual suspension system, I am still running the 1.25" perch collars front and rear, as well as a 1.5" top spacer front and rear. I have not had the 37s on a trail yet to see if that is enough lift. It should also be noted that I have 1.5" wheel spacers on the optional Badlands wheels.

My fingers are crossed that your outcome is sooner. It is an interesting combo the collars and the top spacer, but it will work. My wheels will be 0 offset, so no wheel spacers needed. I look forward to reading your updates. Good luck.

brnc_o_vrlndr

Dec 04, 2023

#16

Well, good news today! The replacement parts came in and the shop has the green light to get more aggressive with the axle removal. Still crazy how stuck that thing is already. Hopefully the next update will be how the gears perform!

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Deano Bronc, Mikes2021Bronco

Dec 08, 2023

#17

It’s done! The gears are in! It’s just waiting for the alignment and I get to pick it up Saturday when I get back from a work trip. Woohoo!

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Deano Bronc, Mikes2021Bronco

Dec 08, 2023

#18

That’s awesome! Congratulations!

brnc_o_vrlndr

Dec 20, 2023

#19

Good morning. Two years, and 60k miles in the Bronco, has come and gone. Due to the Bronco being in the shop for the gear swap, I didn't quite make it to 60k miles before that two year mark, but it was close.

Anyway, the Bronco has been back in my possession for over a week now. I even had an impromptu chance to test it out offroad, though that just turned into a muddy mess. I was able to utilize the crawling capability and extra clearance on a couple hill climbs and it is amazing! I am really looking forward to getting back on the rocks to better test the Bronco. One the street, the Bronco performs very well and no longer feels like I need to slip the clutch to get moving anymore, especially starting from a stop up inclines. The 2.3L does not have a ton of torque in the low end and those hill starts got interesting sometimes. I found myself using the crawl gear to get started in some of those situations.

I definitely need to install the JKS Max Tire kit, as the tire will hit the front crash bar mount when flexing and turning the steering wheel. I did not happen on this trip, but it will. So far, I have not had any issues with fender clearance, which was one of my main concerns. I removed the fender flares so I could better check clearances on occasion, but that meant losing most of my mud control, which is obvious in the attached photo.

A lesson learned, and piece of advise for anyone considering a gear swap, is go ahead and purchase the Ford Performance axle bearing and seal kit BEFORE taking the Bronco into the shop for the work. For a while there, I did not know if the parts were going to be available in a timely manner and all the scenarios began running through my head of not getting the Bronco back for weeks, or worse. The shop was able to finally remove the right rear axle, but it took a lot of heat and "persuasion," which will destroy, at least, the axle seal.

Thanks for the support through this process and I hope to see you on the trail sometime!

"Of all the paths you take in life, make sure a few of them are dirt" - John Muir
"The mountains are calling, and I must go..." - John Muir
BN #0120

Sven, TK1215

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