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Finally sneaked some bronco time, almost got the front axle put together, mixing and matching aftermarket parts is definitely a bit of a challenge, had to trim the axles down a little bit because they were originally setup for a Detroit (no spider gear support pin). I also am running some aftermarket brake dust covers that are thinner than stock, that sucked everything in and make the snap ring on the and of the axle shafts stick out to far for the hubs to fit, ended up making spacers that are about 1/32 thick to make it all work. Added gusset to front axle kind of like a Toyota front axle, skid plate for the bottom, and drain and fill plugs. Still have to sort out trac bar, brake lines, and steering.
This should solve any driveline angles, assuming it doesn't go straight through the oil pan! The front driveshaft should be raised 3.75" (1.5+2.25) and the rear should be raised 4.5" (2.25+2.25). With the 4" of lift I am running in the rear it should make the driveline angle less than factory with no lift. in the front it is a little more complicated because I clocked the transfer case up a couple inches and the ZF transmission makes the drivetrain longer, but it should make it about the same as stock. The drivelines are stock bronco ones with 1310 u-joints, but the high9s came with 1350 yokes, going to run a conversion joint and see how it goes, with the fairly flat driveline angles I could always go to a 1350 based driveline, but I don't expect to need that, the 1310s are probably plenty strong, especially if they don't ever get put in a bind.
For the rear axle, the plan is to weld up and re-drill the ends for the new style 3/8 bolts to work with my Explorer disc brakes. Set the rear pinion angle and weld on the perches and install the brace on the housing, not sure I really need a brace but it was sitting around so might as well use it. Also waiting on a new 35 spline ARB, the first one had a huge casting flaw in the housing.
Finally got the bronco put together enough to load on the trailer and take to Truckee. Thanks for the top Brian, it should have just bolted right on but the roll cage interfered, ended up having to cut and reweld the roll cage pads to move the whole thing forward 1/2", it was either that or drill new holes, which would have been easier, but I had spend so much time filling all the holes in that tub I couldn't stand the idea of putting in any more. In the end I had to postpone getting the e-brakes setup and it is still missing the steering stabilizer but other than that it is back together. It was weird to haul it out of Woodland for the last time, but it sure does look right at home in the mountains. I have noticed that 6000 ft elevation takes the snort out of it though, time for ?!?
Finally got the ARBs wired and plumbed up. I had been thinking about where to put the switches, the ARB supplied ones don't really go with the style of an early bronco, then I found these cool LED switches and a place called Carolina Laser that could make me custom rocker switch "legends" (who knew they were called legends???). Anyway I like the result, went ahead and ordered some for the front bumper lights and the rock lights, now I just have to buy/wire the lights
Thanks guys, we moved to a new place, definitely more bronco friendly with a real shop (not just a garage) and some acreage to play on. So far the axles seem good, no complaints, no weird noises, awesome driveline angles. Although upgraded axles don't really pay off until you don't break them (my dana 30 worked great, right up until it didn't). I will say ARBs are great fun: it drives nice on the street, but I can lock them all up and do 4 wheel slides.
The overall transformation has been fun, the paint is 90% of what people notice, but the mechanical is what I really like. Basically I only painted it so people would notice it enough to ask about the drive train Still have some exhaust leaks to fix and modify the oil pan to clear that huge front differential. Might be doing a snow trip after new years, time to get cracking!
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