BOOcircuit95B.jpg
116 hits | 52.09 KB | Posted: 2/19/24
Brake On-Off (BOO) Circuit for '95 Bronco (others similar)
IF THE IMAGE IS TOO SMALL, click it.

The shift lock is specific to '95-up with auto trans; CHMSL is '92-96 for Broncos, but '94-up for F-series; 4WABS is '93-96 Bronco, but F-series have RAB...
(Posted in: Diagrams)

LEDresistor.jpg
3434 hits | 77.1 KB | Posted: 4/30/21
Brake LED Resistor
IF THE IMAGE IS TOO SMALL, click it.

Since there are many other systems (ABS, cruise, electronic automatic transmission...) that rely on the BOO (Brake On-Off) circuit, there can be many consequences in converting all the brake li...
(Posted in: General Purpose Pics)

EGRTubesV8.JPG
27574 hits | 93.96 KB | Posted: 9/20/10
Replace with
(Posted in: Diagrams)

EGRTubesV8.JPG
62 hits | 93.82 KB | Posted: 4/23/24
EGR Tubes for (early; non-PFE/DPFE) 5.0L & 5.8L
IF THE IMAGE IS TOO SMALL, click it.

1 - Exhaust Gas Recirculation Valve 9D460
2 - EGR Valve to Exhaust Manifold Tube 9D477 (4.9L F4TZ9D477C = [url=https...
(Posted in: Diagrams)

Stethoscope.JPG
10923 hits | 119.07 KB | Posted: 10/5/13
The easiest way to find a vacuum or exhaust leak is with a mechanic's stethoscope. Remove the hard probe (which is used for listening inside hard parts) and attach an extension if necessary. About 3' o...
(Posted in: General Purpose Pics)

Oil Temp Range.jpg
17659 hits | 50.34 KB | Posted: 10/30/05
******The chart above is for 1990s oil. The TSB below refers to MODERN genuine Ford/MC oil only.********
TSB 02-1-9 ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY
Publication D...
(Posted in: TSBs & FSAs (Recalls) for '83-96 Broncos & F150s)

TagEngRHS.jpg
145 hits | 71.09 KB | Posted: 1/25/20
I haven't figured out what happened to that oil fill cap, but I've replaced it.

Engine Family Name (12 digits)
VNV7.3C8DAAA
1 23456789 01 2
(Posted in: Big Red)

Shark01.JPG
1534 hits | 78.84 KB | Posted: 6/13/12
Since factory signal mirrors are so hard-to-find, building them is another option. These LED chevrons were made by Shark Racing (back in 2012, ...
(Posted in: Side Mirrors)

MFS Testing.jpg
24720 hits | 47.47 KB | Posted: 7/17/05
REPLACE with
(Posted in: Diagrams)

WiperValance.jpg
700 hits | 121.91 KB | Posted: 2/26/22
'80-96 Wiper Valance
IF THE IMAGE IS TOO SMALL, click it.

#9 022A48 is only used from '87-97
#11 020A50 is used only on the R (passenger) side '80-95; #14 '96-97 on both sides
#5 022A56 Pad (self-adhesive rubber)
#4 022A68 Wiper Valance (Cowl Grill)...
(Posted in: Diagrams)

ClusterBzlsB94-96.jpg
58 hits | 62.04 KB | Posted: 4/18/24
'94-96 (airbag) Bronco (defrost slot) Cluster Bezels
IF THE IMAGE IS TOO SMALL, click it.

All are brittle with minor damage from use & age like most original bezels, but nothing visible when installed. The registers have been REMOVED for cleaning & ...
(Posted in: Spare Parts)

Voltage.jpg
1448 hits | 90.61 KB | Posted: 2/10/20
Original battery terminals
IF THE IMAGE IS TOO SMALL, click it.
The top 2 are the Left battery; all the others show the Right battery. Probes are either on the CLAMPS (for the higher readings, because the engine is idling & the alternator is the volt...
(Posted in: First Fixes)

20200330_001404.jpg
890 hits | 98.55 KB | Posted: 3/29/20
Because the original terminals were abused, I soldered on some new Copper clamps. I avoided the Lead powder being thrown by the cutting wheel, and used a wood block under the anvil when air-chiseling the old ones off the cables (so I wouldn't shorten...
(Posted in: First Fixes)

20200330_163102.jpg
679 hits | 87.49 KB | Posted: 4/2/20
The negative terminal was easy: after cutting the original Lead clamp away, stripping enough cable to go in the new terminal, and brushing off the corrosion, I dropped the solder pellet in and torched the terminal until the cable dropped in, pushing ...
(Posted in: First Fixes)

BattsTrays24.jpg
74 hits | 108.77 KB | Posted: 2/27/24
After suffering with the batteries that were in it when I bought it for a few years, I decided to do it right for '24. So on Jan 2, before the blizzard had melted, I bought 2 new TestedToughMAX BXT-65-800s and installed them in the dealership parking...
(Posted in: Big Red)

HandleRepairs.jpg
249 hits | 58.46 KB | Posted: 4/5/24
Inside Door Latch Handle Repair
IF THE IMAGE IS TOO SMALL, click it.

After removing the door panel, inspect the skin where the mechanism attaches. If the hinges or latch have been neglected, or if the cable has been greased, excess force needed to o...
(Posted in: Doors)

FSA92S42DoorLatchSeal.jpg
10898 hits | 63.42 KB | Posted: 1/29/07
FSA 92S42 Door Latch Seal
Check the Ford website &/or the NHTSA to see if your VIN is affected.

A...
(Posted in: TSBs & FSAs (Recalls) for '83-96 Broncos & F150s)

Headlight_9296.jpg
1633 hits | 72.19 KB | Posted: 1/3/18
'92-96 & '97 >8500GVWR Headlight
IF THE IMAGE IS TOO SMALL, click it.

The NA bulb goes in the socket with the amber tape on its wiring harness takeout, and lights the clear side lens 15A201.

The headlight bulb connector is WPT-110.

To remove the h...
(Posted in: Diagrams)

HubPts3new23.jpg
68 hits | 85.27 KB | Posted: 1/30/24
New 3-Screw Auto Hub Lock 3-layer Spline Washers, Lock Keys, & C-clips made of AR steel
IF THE IMAGE IS TOO SMALL, click it.

See also:
[url=https://www.supermotors.net/registry/media/1171772_1][img]https://www.supermotors.net/getfile/1171772/thumbna...
(Posted in: Spare Parts)

Door Locks.jpg
6640 hits | 55.36 KB | Posted: 11/23/03
Door lock circuit from the '93 EVTM. All '80-96 (& '97 >8500GVWR) 2-door trucks WITHOUT factory RKE ('94-97 only) are similar.

Note that the lock motors are wired in simple parallel. 4-door trucks simply have 2 more lock motors in parallel, but se...
(Posted in: Doors)

CabSteps5distances.jpg
1805 hits | 130.88 KB | Posted: 5/26/14
Check body mount height & body centering, particularly on the driver's side near the e-brake cable bracket.

See also:
[url=https://www.supermotors.net/registry/media/969977][img]https://www.supermotors.net/getfile/969977/thumbnail/29tubalign.jpg[/im...
(Posted in: Cab Steps)

3BodyMts.jpg
143 hits | 44.07 KB | Posted: 3/28/24
A quick way to check body mounts is to mark the lower isolator & then try to turn it by hand. If it spins, the upper is collapsed, or there's some other problem (rust, collision damage, etc.).
IF THE IMAGE IS TOO SMALL, click it.

See also:
[url=http...
(Posted in: Body Mounts)

BedBoltNew.jpg
40 hits | 88.7 KB | Posted: 1/30/24
Aftermarket long bolt dimensions in mm.
IF THE IMAGE IS TOO SMALL, click it.
(Posted in: Bed Bolts)

BedBolts95new.jpg
44 hits | 50.97 KB | Posted: 1/30/24
Undercoating the exposed threads will protect them from rust, without interfering with removal.
IF THE IMAGE IS TOO SMALL, click it.

The front Left bolt is hardest to see because of the front tank (if equipped).
(Posted in: Bed Bolts)

BedLift96.jpg
57 hits | 96.59 KB | Posted: 1/30/24
I sometimes use this portable gantry (made from scrap metal: a 5" Aluminum I-beam, some 1.5" straight square tubes, and some 2" square tube T's, with common 5/8" hitch pins to adjust the height) with a [url=https://www.amazon.com/dp/B00ID981Z6]12V AT...
(Posted in: Bed Bolts)

ThrottlePlug.JPG
25631 hits | 47.11 KB | Posted: 4/12/08
Throttle Plate Orifice Plug Service Installation

Some steps in the following procedure reference special tools or equipment, but reading the procedure will still be informative, and should allow proper idle speed adjustments using common tools.

[ur...
(Posted in: Diagrams)

Hood Support 96.jpg
50 hits | 71.31 KB | Posted: 4/15/24
Hood Hinge & Support
IF THE IMAGE IS TOO SMALL, click it.

1 Hood Hinge 16796
2 Screw and Washer Assembly N803506-S55
3 U-Nut N800538-S100
4 Hood 16612
5 Link Assembly, Hood Hinge (RH) 16K700
6 Link Assembly, Hood Hinge (LH) 16K702
7 Front ...
(Posted in: Diagrams)

Visor5Cover.JPG
1556 hits | 68.22 KB | Posted: 4/24/11
I cut this cover behind the mirror so the vanity assembly would pass through and the cover could be removed without cutting the wires.
IF THE IMAGE IS TOO SMALL, click it.

For more info on visor upholstery, see this:

[url=http://www.supermotors.net...
(Posted in: Overhead Console & Dual Visors)

52Brushed.JPG
1682 hits | 132.93 KB | Posted: 10/23/14
While the rotor is off the hub, make sure both sides of the flange are thoroughly clean & flat to prevent warping the rotors. It doesn't take much to ruin them.

[url=https://www.supermotors.net/registry/media/881406][img]https://www.supermotors.net...
(Posted in: Brakes & Hubs)

DrumSpec.jpg
320 hits | 85.71 KB | Posted: 1/29/22
Brake Drum Wear Limit Specification is stamped into drum lip
IF THE IMAGE IS TOO SMALL, click it.

282.45mm = 11.12"
(Posted in: Brakes & Hubs)

RotorRmv4WABS.jpg
366 hits | 49.93 KB | Posted: 8/29/22
4WABS Rotor Removal
IF THE IMAGE IS TOO SMALL, click it.

If the rotor must be replaced on a '93-96 Bronco (4WABS) hub, the tone ring often causes problems because it's not easy to pull with a 3-jaw puller, and replacements are not available new. But...
(Posted in: Brakes & Hubs)

FSA01M05FuelCrossFlow.jpg
30672 hits | 49.86 KB | Posted: 6/17/09
FSA 01M05 Fuel Cross-Flow
Check the Ford website &/or the NHTSA to see if your VIN is affect...
(Posted in: TSBs & FSAs (Recalls) for '83-96 Broncos & F150s)

CruiseVacPedals.jpg
209 hits | 104.9 KB | Posted: 2/23/24
'92 Vacuum Cruise Pedals Details
IF THE IMAGE IS TOO SMALL, click it.

See also:
. [url=https://www.supe...
(Posted in: Diagrams)

ClutchPedalPosSw.jpg
8628 hits | 52.03 KB | Posted: 7/5/12
Clutch Pedal Position Switch '87-96 is installed on the clutch MC pushrod above the gas pedal.

1 - Lock Tabs (part of Retainer Plate)
2 - Retainer Plate
3 - Catch (part of Clutch Master Cylinder)
4 - Pushrod (part of Clutch Master Cylinder)
5 - Clut...
(Posted in: Hydraulic Clutch)

LightningOptions.jpg
93 hits | 103.7 KB | Posted: 2/21/24
'93-95 Lightning F150 (509A) Option List
IF THE IMAGE IS TOO SMALL, click it.

Although indicated here as unique to Lightning: color-keyed bumper & grill were available on XLTSport; HD E4OD was available with diesel; and though the Lightning upholste...
(Posted in: Diagrams)

Crossdrilled&Slotted.jpg
5593 hits | 8.08 KB | Posted: 1/13/06
Cross-drilling is only for looks. On race cars, it reduces weight, but on trucks, it only makes the brakes run hotter because it removes thermal mass. Slotting was originally done to release gasses generated by organic lining material, but modern p...
(Posted in: Brakes & Hubs)

InteriorCleaning.jpg
71 hits | 57.79 KB | Posted: 4/10/24
The carpet & upholstery were nasty, so they all came out & got hosed down.
IF THE IMAGE IS TOO SMALL, click it.
(Posted in: First Fixes)

Slider97F250hD.jpg
70 hits | 83.59 KB | Posted: 3/23/24
Rear Window Slider
IF THE IMAGE IS TOO SMALL, click it.

I've had this window for over a year, but I just got around to swapping it in. Silicone grease on the body & gasket lips make installation easier, and prevents leaks by allowing the rubber to r...
(Posted in: Big Red)

RS22-172DMM.jpg
4984 hits | 59.55 KB | Posted: 2/1/16
Radio Shack 22-172 (Model 2200172, UPC 040293278861) True-RMS Digital Multimeter with high-current AC/DC clamp

There are MANY better brands & meters available, but for what it does, this one is surprisingly affordable. Particularly: True-RMS ACV & ...
(Posted in: General Purpose Pics)

BumperF92-96Arms.jpg
45 hits | 44.3 KB | Posted: 2/17/24
'92-96/7 Front Bumper Arms & (Bronco-only) Brace Plates
IF THE IMAGE IS TOO SMALL, click it.

This page & the NEXT few show how to straighten the frame tabs:
[url=https://www.supermotors.net/vehicles/registry/media/859668][img]https://www.supermotors...
(Posted in: General Purpose Pics)

Spindles83-96.JPG
9681 hits | 72.51 KB | Posted: 5/6/09
Spindle Differences '80-96

In addition to the ~'92 loss of a spindle stud (leaving 5) and the addition of 2 notches in the spindle flange for the (Bronco only) 4WABS sensor used on '93-96 Broncos only, the spindle was also redesigned in ~'95 to matc...
(Posted in: Brakes & Hubs)

Projectors.jpg
83 hits | 88.96 KB | Posted: 2/29/24
These are so good, that I put them on all my trucks. I liked the way these trucks looked originally, but I'm so used to seeing them this way that they look normal to me with these headlights. And judging by how many others I see on the roads, most pe...
(Posted in: Headlights)

Rnfrc12.JPG
2056 hits | 61.51 KB | Posted: 10/19/09
Using the predrilled holes as a guide, I installed three 3/16" rivets. The reinforcement where the brace rests isn't flat, but it should still work. It would be better to scuff everything to bare metal & add panel adhesive (like [url=http://ww...
(Posted in: Right Side Split)

Rnfrc15.JPG
1849 hits | 85.43 KB | Posted: 10/19/09
The 3 rivet heads are directly under this end seal, but they're flat enough not to interfere with it.

The fine lines along the outboard edge are from the pliers I used to crimp the lip tight before installing the black rivet. I'll touch them up aft...
(Posted in: Right Side Split)

95BXLT-tgsplit.jpg
216 hits | 63.76 KB | Posted: 11/14/21
Since this t/g isn't broken yet, I'm just riveting the skins together. After clamping the skins carefully with Irwin QuickGrips, I drilled a 1/4" hole where it won't be visible, but where it's stil...
(Posted in: Right Side Split)