4bt cummins in bronco help needed

[4x4jumper]

hello, i have been searching and searching to find information and have not found exactly what i need.
ok so I am hopefully going to be getting 2 broncos (1 parts and 1 to built but is rust free). If i get them then i will be putting a 4bt in so that i can get 25-30 mpg as this is going to be my daily driver. anyways here are my questions...

1. I do not care if it is a manual or auto but i would like to avoid cutting the frame if possible, what transmission should i look for?

2. what kind of engine mounts and mods will i need to do to install the engine?

i have more but got to go... thanks!;D

 

[broncodriver99]

Do a forum search. There are a couple of members running 4bt's with build threads. Papitt is one I know of and is a good guy. Could probably answer a few questions for you. Here is one of his threads. I'm getting ready to start a diesel project myself so should be fun.

http://classicbroncos.com/forums/showthread.php?t=143913

A bronco does have the aerodynamics of a brick so I doubt you will get near the 30 MPG mark.

 

[broncnaz]

There's probably a few threads that have some of the info your looking for. Might want to do a search. Tranny makes pretty much no differance I dont know of any that require cutting the frame. although your going to want a OD tranny in either case. Although I would think a manual tranny might be a easier install and you wouldnt have to worry about torque converter issues. A lot depends on what block/adapter plate/flywheel or flex plate you get with the engine.
Most of the 4BT conversions I've seen up close did have frame mods to fit the engine in. There was a write on the conversion in a old issue of Bronco driver magazine you should be able to get a back issue might provide some insight as well.

 

[gpete]

hello, i have been searching and searching to find information and have not found exactly what i need.
ok so I am hopefully going to be getting 2 broncos (1 parts and 1 to built but is rust free). If i get them then i will be putting a 4bt in so that i can get 25-30 mpg as this is going to be my daily driver. anyways here are my questions...

1. I do not care if it is a manual or auto but i would like to avoid cutting the frame if possible, what transmission should i look for?

2. what kind of engine mounts and mods will i need to do to install the engine?

i have more but got to go... thanks!;D

I am doing a 4bt swat myself the minimum you would need is to cut your engine mounts , 3.5 suspension lift , 2in body lift , i am going to use the ZF 5speed that came in the ford F 350 it would bolt to the engine using the ford adapter clutch is the same. The dana 20 would work with an aftermarket adapter for $400 i decided to use the ford NP 205 transfer case that is a direct bolt on to the zf 5 speed transmision and dont have to spend $$$$ on adapters, the 4btswaps.com web site have alot of broncos with the cummins engine and you can get 25MPG as a daily driver

 

[dantheman222]

I have around stock height suspension and a 3 inch body lift, with stiffer springs cut down from a 77 F150. I had to modify the oil pan extensively to gain clearance around the frond D44, and I also had to run a Wild Horses scooped hood to gain clearance for the intake. A few tips. Find a complete engine from a Bread Van that originally came with a 300 six cylinder if you can. You can get motor mounts from any pickup that came with a 300 and directly weld them in. Then you can use the flywheel and adapter plate to bolt up any transmission with a 300 or small block bell housing. I am using the Mazda 5 speed that is very common in F150s. If you are doing hardcore wheeling I would recommend the ZF though, but they are much more expensive. Think like $100 - $150 for a Mazda. One more tip is that you can interchange alot of parts from 6bt, I have a HY35W turbo from one which gives much quicker throttle response and 23 lbs of boost ;D, also I have installed the intake with its grid heater wired to a push button. I would highly recommend this if you live in a cold climate as Cummins don't have glow plugs this is their cold starting solution. Also 6bts have a larger more effective harmonic dampener that cuts down on the vibration alot. Be a little bit weary of really high mileage engines. We have installed 3 4bts in different vehicles all with over 300 thousand on them and they all had broken rings. They all still ran but started hard and were down on power. A $400 rebuild made a WORLD of difference in starting throttle response and general runability. All of my engines did have the original pistons, rings, and bearings when we tore them down, so they can be expected to run that long without any major work. Also find a service manual, there is one posted online somewhere it is linked to from 4btswaps.com it is very helpful in adjusting the valves, injector pump etc.

Good luck, this engine makes a very torquey engine with terrific mileage and perfect for a DD.

 

[dantheman222]

If you got lucky and found a 4bt that was a replacement for a small block, it would physically bolt right in...

 

[4x4jumper]

thanks everyone!!!

i will try to wait for the right one so that i dont have to spend the $$$$ for adapter plates.
any good search words for finding a 4bt with the ford adapter?


thanks!

 

[70_Steve]

This might be some interesting reading.

http://www.dieselpowermag.com/features/ford/0709dp_1966_ford_bronco/index.html

 

[4x4jumper]

This might be some interesting reading.

http://www.dieselpowermag.com/features/ford/0709dp_1966_ford_bronco/index.html

that is where I get most my questions except at this spot http://www.4wdandsportutility.com/features/bronco/1004_4wd_1966_ford_bronco/index.html

he now has a r4100 and says he had to notch the frame to fit the old NV4500?

thanks

 

[dantheman222]

The bellhousing adaptor from a Dodge HD Cummins pickup truck will allow you to bolt up to the Dodge Automatic or a NV4500, otherwise the Ford adaptor plate is Bread Van specific, they sell them on Ebay, or you need to find a complete van. The bodies all look the same but the frame and chassis is either a Chevy P30 series or a Ford something or other. Its a little confusing the Chevy chassis have a different turbo orientation and a slightly tilted motor than the Fords. I ended up using an engine plucked from a Chevy because the turbo orientation fit better, but we used some other parts off of an engine from a Ford to convert to a Ford alternator and a Ford bellhousing adaptor, along with the above mentioned parts from a Dodge, so its kind of a "hybrid" engine lol.

 

[Pa PITT]

I found my motor from a chevy bread truck ..I believe I have 1800 in it now.. Then I gave 500.00 for the Ford stuff .. Cummins to ford bell housing ..bell housing .. flywheel... clutch.. pressure plate ..all the forks bolts and slave cyl..and a T18 or T19 trans ..Starter..All for 500 bucks... I already had a NP435 in my Bronco with the AA Adapter set up for the Dana 20 ..So I'm going to say with this set up to start it up...
....I have gathered up while I worked for dodge .. I have everything to go to a NV4500 5 speed .. the dodge flywheel and the dodge bell housing ... But I'd like a stronger transfer case for this set up..
....I believe the 5 speed is needed if yours is to be a daily driver..Mine will be a farm truck so the NP435 should work fine for me .. I am only hoping for 20 MPG..
....My motor mounts I welded up .. grind then weld some more ... took a good week to make me happy ... The oil pan is a real pain to get around the pumpkin. And I expect to have to take another inch out of mine .. I built some 3.5 in extentions for my bump stops to keep the pan an punkin from playing tag. I have really tough springs .. I seem to be lifted about 2.5 or maybe 3.5 in the front with 1 1/2 body lift .. My hood shuts stock ..So I'm happy about that ..
....I did notch out at the frame for the starter ..And my front cross member was cut out By a mech I had working on it a little while .. I was shocked he's cut it out ..With out asking me but it was gone so I spent the winter looking at it an putting it back in .. Some welding and some bolting ..
.....It's getting a complete body wiring harness.. I'M going to use a stock 2000 dodge lift pump mounted under the driver seat by the frame as my pump .. Guys on 4btswaps.com say it's not the one to use But the man at the Diesel Injection Pump Rebuilder says it'll work fine.. So I'm going to bet on him..He's been building for 40 years.
...If You have questions maybe I can help answer some .. I have a post going here called 4BT Progress I try to post up on every few days..