'94 Bronco build

5thgen_junkie
Jun 09, 2024

5th gen junkie

Jun 09, 2024

I hope this is the right place for this post. This is to all of us young folks trying to keep the old rigs on the road. I hope by sharing this it encourages more of us to just start working on our rigs even if we are not subject matter experts. I bought my bronco in high school (2017) with 250k miles on it. Since then a lot has changed in my life except for this truck. It has become a huge part of me and I know there are probably a lot of you who can relate. This bronco has seen quite a few relationships come and go over the years, kept me sane after losing a parent, watched me join and leave the military, has taken me across many states, has thousands of hard off road miles and camping trips on it, towed all sorts of stuff it should have never towed, and a lot more memories that you can't replace. My bronco has 290k miles on it now and has never left me stranded. It has been more reliable than most people in my life have been. Even today she still coughs to life every time I ask her to. Mechanically speaking all the internals are stock from 1994. If any bronco deserves a full rebuild its her. Since 2017 I have been reading, planning, and waiting for some mentorship when it comes to "old school" DIY engine building. The ones in my family have passed away before they could pass any knowledge to me so now I have two or maybe three generations of tools laying around that have built countless Mopar, Chevy, Pontiac, and Ford engines over the decades. Instead of waiting around for someone to teach me how to build my dream 331 stroker I am going to dive into this head first and see what happens. If I can pull this off then anyone with half of a brain can do the same thing. I know nothing about engine rebuilding other than insane amounts of internet knowledge.

So here is my very rough internet search inspired plan. I have bought two 5.0 engines from a local junkyard for about 500 bucks. One for sure runs and the other I am not sure. Both have the GT40P heads. The engine I am not sure about running will be my attempt at a 331 stroker build and if I absolutely ruin that engine somehow to where I can't use it then I will do a nice 302 rebuild on the running engine because I am assuming that will be easier. Still looking for a good machine shop for the blocks but once I find someone I trust and gives me an inkling of hope that they know what they are doing then I will start ordering parts for this build. Here is a list of parts I have collected over the years and we will see if it works out.

https://www.scatcrankshafts.com/product/1-45155/

I want to update the EFI system on my build and I talked to Pro M and they said they have had many 5th gen bronco owners successfully run their engines with their EFI systems.
https://www.promracing.com/pro-m-efi-universal-hotrod-engine-management-system.html
https://www.promracing.com/pro-m-80.html

Since they don't have a direct plug and play system for the broncos I might have to get creative with sensors / connectors.
https://www.promracing.com/parts-accessories/pro-m-racing-replacement-sensors.html

I plan on porting the heads on my own but this is the cam I want to run. Not really sure yet what else I need to upgrade in the heads to make this work but I willing to replace as much as I need to in order to get another 200k reliable miles.
https://www.jegs.com/i/JEGS/555/200540/10002/-1
https://www.summitracing.com/parts/cca-972-16
https://alexsparts.com/new-sb-ford-...max-output-ii-530-lift-hyd-roller-vsk7f49-m2/
https://www.summitracing.com/parts/tfs-250010

Lastly I have the E4OD and I will need a standalone system if I change the stock computer and it seems like this will do the job.
https://www.usshift.com/usq4rd.shtml

This will take a while to fully complete but I will do my best to update you all.
Jakob1972, Kenneth

Rank IV

Jun 09, 2024

#1
Have you thought of just going with a crate engine?
No salt tram towers were harmed in the making of this post...
Kenneth, Lots O Fords

Rank IV

Jun 09, 2024

#2
Welcome and please keep us updated on the build.
I still have a 93 that I bought new. It was very reliable and I just can't seem to part with it
I was quick to repair anything so it always looked and ran well.
I always kept it stock.

Then around 300,000 I decided to go through the engine. Did Edelbrock heads, cam, intake. Roller rockers, headers and more.
That engine lasted about 10k. It kept blowing a head gasket. The machine shop bit me
So I got a brand new short block from Ford. Same Edelbrock upper end (their performance kit for that engine)
Something about the heads has made the fan belt not aligned.
The performance sucks and the fuel mileage tanked.
I so regret modifying it. I just wish it was back to a bone stock 351.

I worked in the automotive repair industry as an ASE master tec and shop manager for over 20 years. Built many engines, all stock.

In my opinion, that fuel injection and ignition system is so limited engine modification is wasted.

I truly hope your experience is better than mine. My dream for the ol girl is a stock reliable 351.
Kenneth, Deano Bronc

5th gen junkie

Jun 09, 2024

#3
Have you thought of just going with a crate engine?

I have but I will learn way more by building my own engine. Obviously not going with a crate engine makes my life harder but its all good lol.
Kenneth, Deano Bronc

Rank IV

Jun 09, 2024

#4
The machine shop is key.
The one place you never skimp or shortcut.
Kenneth, Deano Bronc

5th gen junkie

Jun 09, 2024

#5
Welcome and please keep us updated on the build.
I still have a 93 that I bought new. It was very reliable and I just can't seem to part with it
I was quick to repair anything so it always looked and ran well.
I always kept it stock.

Then around 300,000 I decided to go through the engine. Did Edelbrock heads, cam, intake. Roller rockers, headers and more.
That engine lasted about 10k. It kept blowing a head gasket. The machine shop bit me
So I got a brand new short block from Ford. Same Edelbrock upper end (their performance kit for that engine)
Something about the heads has made the fan belt not aligned.
The performance sucks and the fuel mileage tanked.
I so regret modifying it. I just wish it was back to a bone stock 351.

I worked in the automotive repair industry as an ASE master tec and shop manager for over 20 years. Built many engines, all stock.

In my opinion, that fuel injection and ignition system is so limited engine modification is wasted.

I truly hope your experience is better than mine. My dream for the ol girl is a stock reliable 351.

Yeah. The MAF trucks EFI systems can sort of adjust but even then they are just limited. I know someone who had a 302 bronco and they put a hopped up 351 in it and ran it off of the stock 302 computer. Every now and then it has "episodes" because it can't figure out what is going on with the engine. Over time stuff has been changed in the wiring harness or sensors to help out the computer but I just don't want to deal with that. Also if I update the EFI I can essentially run a custom OBD2 setup which makes life way easier. Ive heard nightmare stories about engine builds going south and seen other go through that new engine troubles. I have accepted the fact I will probably have my version of that and I will just deal with it as it comes.
Jakob1972, Kenneth

Rank IV

Jun 09, 2024

#6
Yeah. The MAF trucks EFI systems can sort of adjust but even then they are just limited. I know someone who had a 302 bronco and they put a hopped up 351 in it and ran it off of the stock 302 computer. Every now and then it has "episodes" because it can't figure out what is going on with the engine. Over time stuff has been changed in the wiring harness or sensors to help out the computer but I just don't want to deal with that. Also if I update the EFI I can essentially run a custom OBD2 setup which makes life way easier. Ive heard nightmare stories about engine builds going south and seen other go through that new engine troubles. I have accepted the fact I will probably have my version of that and I will just deal with it as it comes.

I sure hope your build goes smoothly.

Mine came with the 351 originally and it was very reliable.
Kenneth

KCsBronco

Jun 10, 2024

#7
Yeah, finding a good shop's both important and difficult. Last year, a friend's son completed his precision machining associates degree from Warren Tech. He hasn't been able to find anything with his degree, works at a local lake rec operation renting paddle boats in summer and ice skates in winter..

Cheers
Deano Bronc, Lots O Fords

The Mighty Neptune

Jun 11, 2024

#8
pictures please 😀

Rank IV

Jun 11, 2024

#9
Yeah, let's see some pictures of your rig @5thgen_junkie
Jakob1972

Gladesmen

Jun 11, 2024

#10
Man good luck. that sound like one heck of a Bronco story.
I wish I still had my 84.
Be prepared for a lot of fine tuning with those stand alone controllers. I have a 2004 F250 Fummins that I have been fine tuning for about 14 years now. LOL
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
Lots O Fords

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