Izzy's build... Time to say goodbye...

[Izzy]

Renamed to Ugly Brown Build to server as my build thread. Renaming my build again. I didn't like the old one. I'm going simple here. Izzy Build Up. Lets see how long I like this name... The last name lasted a while but this new one is it

TOC:
Pages 1-6 cover NV3550 Swap Project.
Page 15- tbd cover Explorer Engine Install

Got everything ordered today and on the way. I'm excited about this upgrade. Ordered the transmission locally at a good shop, and the conversion kit from Wild Horse. I threw in the D20 rebuild kit too, figured while I have it out, I might as well rebuild it.

everything should be here and ready by mid week so I'll get started on this next Thursday 8/26 and hope to have it done by Sunday.

Anyone in the North Dallas area free to help me out with this project? All beer and food will be provided...

 

[tcb42]

Good luck with it. Hopefully you have better luck then I did with mine. First gear broke leaving my driveway. Got a replacement but never got around to swapping it out yet. Other than that I'm happy with it and it was a pretty straight forward swap.

 

[DRBRONCO69]

You will love the conversion!

Note: Dry fit the transmission, adaptor and transfer case on the ground first. The adaptor has multiple holes drilled for clocking the transfer case and if it is not clocked correctly, there will be one or two bolts that you won't be able to install. Fit them together so all the bolt holes line up then mark the adaptor and case. It will then be easy to figure out where the case needs to be when you finally install it together while on the truck. Hope that makes sense.

 

[Izzy]

Thanks for the tips guys. And hopefully my first gear won't break, that would be a huge downer.

Where are all those Texas boys?

 

[ET]

I'll give you a hand if I'm free. Never done a tc rebuild though so I would love to learn.

Eugene

 

[Izzy]

Hey guys, Do i need a tranny jack specifically or can I use a floor jack? What is the difference?

 

[broncodriver99]

If you have a floor jack you could get something like this.

http://www.harborfreight.com/floor-jack-transmission-adapter-39152.html

Makes it much easier.

 

[rjrobin2002]

Wait till you get to attach the 4 bolts from the front T/C yoke to the front driveshaft CV. I did this yesterday and it is an hour process to tighten 4 bolts, and thats with me cutting my 1/2" wrench in half and with it on a car lift. Gonna have to go get me a replacement at a pawn shop now. Mine had the NV-3550 in it when I got it.
Make sure you put at least a 1" body lift on it so you dont have to cut a huge hole in the floor. I recommend the replacement body mounts with the 1" lift built into them.

 

[73stallion]

they only weigh just over 90lbs, i usually just get them on my chest and benchpress them in. seriously!

 

[tcb42]

they only weigh just over 90lbs, i usually just get them on my chest and benchpress them in. seriously!

That's all I did too.

 

[blubuckaroo]

I'm trying to understand the issue in MarsChariots 3550 tech article about the bell housing. I'm refering to figure 10 there he had to shim the bellhousing because it wasn't true to the flywheel. What is that about?

 

[Izzy]

I'm trying to understand the issue in MarsChariots 3550 tech article about the bell housing. I'm refering to figure 10 there he had to shim the bellhousing because it wasn't true to the flywheel. What is that about?

I'm not sure about this one yet but will let you know next weekend.

 

[Izzy]

Today was a fun big day to start off the swap. Before I get into it, I just want to say a huge thanks to Eugene (ET) who spent all day at my place with me getting everything out of the Bronco. His experience and tips and help was invaluable. Once again, thanks so much Eugene.

As for what we accomplished today, we removed the driveshafts, then the mufflers, then the skid plate, crossmember, transfer case, tranny, bell housing, clutch, and flywheel. I learned alot during this process and again, I owe all of that to Eugene.

Here are a few pictures to share. Not a ton to discuss though as everything came out pretty nice and easy. Now it's time to get some parts cleaned up and ready for new parts to arrive for the install. I'm pretty excited though. This has started out as a very fun project.

Next steps, clean and prep the D20 for the rebuild, resurface the flywheel, and get the driveshafts rebalanced and slip yokes checked for possible replacement. They are currently very loose and wobble on the driveshaft.

Enjoy the pics.

 

[Dan74Bronc]

Not a ton to discuss though as everything came out pretty nice and easy.

I hope every thing goes together as nice and easy but that has not been my experience. These old Broncos fight back sometimes.;D
Good luck and keep us posted.

 

[G's Baja Bronco]

looking good, keep up the fight ;D

 

[ET]

I'm glad I could help out and Izzy was a good host. I did warn him about the install but he should be fine if he has all the parts. There's some good suggestions already posted.

I had fun to be able to work on a bronco. It's been a while. I was pretty surprise how easy everything came out. A few stubborn bolts, chat w/ neighbor and chasing some tools kept us from finishing early. Good time.

Eugene

 

[Izzy]

No better excuse than a project to pick a few new tools. As Eugene mentioned, I had to borrow a few tools to finish the job, well I fix that today, went to the tools store and picked up everything I didn't have and then some more. I'm good to go tool wise for the install... I hope...

 

[blubuckaroo]

No better excuse than a project to pick a few new tools. As Eugene mentioned, I had to borrow a few tools to finish the job, well I fix that today, went to the tools store and picked up everything I didn't have and then some more. I'm good to go tool wise for the install... I hope...

Clutch alignment tool?

 

[Izzy]

Clutch alignment tool?

There is always something.

No I did not get one of those. What else will I need?

 

[ET]

Your getting a new clutch so it should come w/ it. Double check when you get it.

Eugene