'Buddy'

[landshark]

You can drill the bolt out or they make extractors that you can pick up at the part store in different sizes. Then Chase the threads with a tap

[Gunnibronco]

I had one broken off in each side of the frame, so only 3 bolts per side, maybe since I owned the truck. I might have broken one off myself. It will probably be fine, if you don't want to mess with it.

[BroncoRaider]

Awesome, thanks guys.

[mickphatmac]

Just did manual to auto conversion...3 on each side as well, Not worried!
At some point I will probably drill and tap.

[sykanr0ng]

If it's not broken off down inside a hole then weld a nut on it.

You get a head for a wrench and the heat may help loosen it.

[BroncoRaider]

Phil and Jeff were kind enough to donate some time to teach me engine building this weekend. We had two hiccups that you can see in the first two pictures. 1. while cleaning out the threads in the block, 3/4" of the tap broke off. 2. Due to a torque wrench malfunction, we stretched a couple of the main cap bolts and went on a 2.5 hour drive looking for replacements.

All clearances checked out fine on the bottom end. pistons went in without a hitch.

Then we realized that the head dowels, air injection plugs, and rocker nuts did not come back from the machine shop with the rest of the parts. Also realized that the rebuilt torque converter I bought does not have a long enough pilot to engage the crankshaft properly. We weren't able to finish, but we got it far enough along that I can finish it up this week once I get the rest of the missing parts.

HUGE thanks to Phil and Jeff for time and space this weekend.

[BroncoRaider]

Got the dash put back in place! Thanks for the help Chuck!

[Eck]

Nice Tim. Keep chipping away. How is the engine coming along?

[Brent13]

I am about to pull my dash, doing a Painless harness install as soon as it arrives. I am not looking forward to getting my dash out! Does the column have to come out for dash removal?

Thank you

[BroncoRaider]

Eck,
Engine will get finished up this week. Have to find some locking 5/16" rocker nuts. Apparently when every website tells you the 3/8" will fit your 1975 Bronco, they're all wrong...

Brent,
I actually got the dash out without removing the shifter, but I did remove the turn signal arm. It took some tricky maneuvering, I wouldn't recommend that route. The shift arm is held in with a roll pin and the turn signal arm just screws in. Remove those and the wheel and it's cake. A second set of hands makes it much easier. The screws in the back of dash are tough to get to as well. Tech article: http://classicbroncos.com/tech/removing ... ronco-dash The painless harness is great, very good instructions. It's all pretty fresh in my mind, give me a shout if you have any questions.

Tim

[ZOSO]

Eck,
Engine will get finished up this week. Have to find some locking 5/16" rocker nuts. Apparently when every website tells you the 3/8" will fit your 1975 Bronco, they're all wrong...

Tim

I may have some in my parts bags. I'll dig through them tonight and let you know.

[ZOSO]

I have the rocker arm nuts I pulled out of my 351. My new heads are 3/8 studs. Where are you located?

[BroncoRaider]

Aurora, near the medical campus.

[BroncoRaider]

A little of everything today, I tried to mate the 302/c4, not much luck. I couldn't get the entire bellhousing to line up straight, and it was causing some binding issues that wouldn't let the crankshaft turn. Gonna try to find a transmission jack to rent and give it another go in the next couple of days.

My carb spacer was so full of "junk" that it cracked. The EGR is full of the same stuff. Solid, packed, nasty.

I did install the collapsible lower steering shaft from Tom's, a new cowl seal, and a new liftgate to tailgate seal, so it wasn't a total waste...

[landshark]

I have a Trans jack you can use if you want.

[BroncoRaider]

Thanks to Landshark's trans jack, got the c4 mated to the block. So simple when you have the correct tools.

Also attached a pic of the TBP lower steering column.

Plan is to stab it in on Saturday and finish up a couple of other items on my list. The big issue right now is the carb/intake. Can I run the stock carb without the spacer/EGR? If not, does anyone happen to have one of the spacers in a box that they would be willing to share?

I've decided that I'm just going to cap off the driver's side fresh air box for now, maybe I'll replace the vent box someday...

[EFI Guy]

I'm guessing you need one from a 2 bbl? I know I have a 4bbl one, will check on the 2 bbl this weekend during my big garage cleaning event.

[BroncoRaider]

Thank you to Jeff, Chuck, and Chris for coming over and making sure I didn't kill myself putting the drivetrain in.

Made some great progress today.
1) 302/c4/d20 installed, along with rear driveshaft.
2) Bolted on headers and starter.
3) Hooked up dakota digital oil pressure and temp sensors as well as the VSS. (Now ready for the gauge cluster to go in!)
4) Ran wire looms to the rear of the vehicle. (I ran the loom down the inside of the driver's frame rail, should it follow the same path all the way to the back?)
5) Bolted on Explorer front dress brackets. (I put washers under the motor mounts for pulley clearance, turns out it would've cleared anyway)

With the headers, the oil dipstick will not fit, anyone have a recommendation for a flexible oil dipstick? I was looking at this one: http://www.amazon.com/68052-Dipstick-Fl ... form+68052

Going to try and get some more accomplished this week. Thanks again for coming up this morning guys.

[Viperwolf1]

Looks good, except for the kickdown lever which is upside down.

[BroncoRaider]

Phil,
I mentioned to Jeff that I thought I put it on upside down. Your eye for detail never ceases to amaze.

[Rox Crusher]

It was fun working on such an original rust free Bronco !

[Eck]

I just bought this if you'd like to use it to check fit before buying something...

I'm not sure if it will fit yours though as it says it's for a 351.

I can bring it with me regardless when I come help in the next couple days.

[Justin]

If he doesn't take it i might.

[Eck]

If he doesn't take it i might.

I'm not getting rid of it- but I plan to install it probably later this week so if you want to use it to decide if you want to order one, you're welcome to.

[BroncoRaider]

First weekend at home in a few weeks, made some more progress

Ran the loom to the rear and connected tail lights, and plumbed the new fuel line.

Plumbed the trans cooler lines. Had a heck of a time with this, one of the lines twisted and snapped when I was removing the C4. Got the piece out of the transmission and it was sitting with the old line for 2 months. When I cleaned up a few days ago, this small piece was swept up and thrown in the dumpster, with the C4 adapter still attached.... I thought I found the right adapter at NAPA, but alas, it was incorrect and I had to go dumpster diving. Found the end with the adapter, soaked it in PB blaster and finally got it apart and reinstalled with the new line.

Radiator is back in, I took Rox's advice and used the 4.8 Crown Vic upper hose, and the 7.3 Super Duty lower. I need to trim both, but I think they will work. I definitely need to add the shroud extension to make sure the fan steers clear of the lower hose.

Got both the C4 dipstick and the fancy Lokar oil dipstick in, I need to figure out how to keep the Lokar from contacting the headers.

Tomorrow I'm hoping to get the gas tank and fuel pump installed.

[ZOSO]

What year Crown Vic upper hose is that?

[BroncoRaider]

'98 Crown Vic with 4.8L, Gates 22392.
https://www.amazon.com/gp/product/B000C ... UTF8&psc=1

[Rox Crusher]

Lookin good !

[BroncoRaider]

Picked up my "new" seats from the upholstery shop. They were in an accident and blew out the side curtain airbags, one new piece of vinyl on each side and they are ready to go. I've got to sort out the wiring for the heaters, but it looks very easy...

[landshark]

They came out looking great!