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1993 Ford Bronco - In Process

Posted in Features on November 3, 2014
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We heard Alan Schneider’s ’93 Ford Bronco before we saw it. Based on the noise it was making we thought it was a delivery truck, but when we craned our necks to have a look, we saw a Bronco. Yep, Schneider’s rig is Cummins 4BT powered. While 4BT conversions aren’t unusual (we’ve recently featured a Jeep CJ, Chevy S-10, and K5 Blazer with 4BT conversions), this is the first time we’ve seen one transplanted into a Bronco.

Schneider, a farm mechanic/fabricator by trade, is also the current president of the Flat Broke & 4 Wheelin’ four-wheel-drive club in Oregon state. His wife owns a landscape business and she used the Bronco in stock form for six years as a work truck. When she replaced the Bronco with a ¾-ton pickup she gave the Bronco to Schneider. “When I took control of the Bronco it had 243,000 miles. The stock engine died two months later,” he says. This unfortunate development was the catalyst for the diesel swap. “After contemplating the cost of building up the 351 engine and the E4OD transmission versus installing a Cummins diesel with a five-speed overdrive manual transmission, the diesel was cheaper,” Schneider notes. He found a 4BT Cummins engine in a Ford chassis Frito-Lay delivery truck for $2,500 and a ZF five-speed transmission for $500. “Since the Cummins was from a Ford chassis, it had the adapter for a small-block bellhousing and hydraulic clutch. Twenty-five dollars got me a manual clutch and brake pedal assembly. I fashioned some simple frame pads for the Cummins mounts that were already on the engine,” he says.

One of the benefits of the Cummins engine is that if he’s easy on the throttle the rig returns 25 mpg. Schneider also says that even with 3.54:1 gearing and 37-inch tires, the rig can hold high speeds on steep coastal grades.

The rig is currently in the process of being built up, but that hasn’t kept Schneider off the trails. He reports that he recently hammered the Bronco on the infamous Hammer trails. “There was no damping left in the shocks, and one of them pulled out of the mount and bent 90 degrees,” he says.

With the buildup in full swing, Schneider is jazzed to report that he recently scored big at a four-wheel-drive swap meet. He brought home Ballistic Fabrication suspension joints to go with an upcoming Dana 60 front axle swap; a disc brake conversion kit for the rear Dana 60; a set of 17x9 Ultra aluminum wheels; and a new Yukon Grizzly locker for the rear Dana 60.

Sounds like the process won’t take long at all.

The four-cylinder 4BT Cummins turbodiesel engine has had some mods to enhance its power. “For more street and sand dune fun I replaced the factory turbo with one from a 2003 six-cylinder Cummins. I re-clocked the housings of the turbo and mounted it on a six-cylinder exhaust manifold that had the two front runners chopped off and capped. I did this so the bigger turbo would clear everything. Because the manifold is cast I had to be careful while welding the 3⁄8-inch-thick cap on the end that I cut off. I welded the plate on three tacks at a time until it was done. I did this over an eight-hour period with my MIG welder. The cast never got too hot. I have had no leaks with over a year of doing this modification,” Schneider says. He also says that he rotated the stock fuel pin 90 degrees for a more aggressive fuel ramp and he turned the fuel enrichment screw in a couple of turns. “For the vacuum and power steering sources I obtained the vacuum/power steering pump combo from a Cummins-equipped Dodge and bolted it in place. I’m not a fan of hydroboost systems because it’s too hard to steer when on a steep hill with the brakes nailed. The Dodge power steering pump seems more powerful than the Ford and it doesn’t have that annoying whine,” he notes. The exhaust system uses a 3-inch-diameter downpipe, 4-inch-diameter exhaust tubing, and a glasspack muffler.

At A Glance
General
Vehicle: 1993 Ford Bronco
Owner: Alan Schneider
Stomping grounds: Silverton, Oregon
Build time: 2 years

Drivetrain
Engine: 3.9L Cummins 4BT I-4, HY35 turbocharger
Transmission: ZF wide-ratio 5-spd manual
Transfer case(s): BorgWarner 1356
Low range ratio(s): 2.69:1
Crawl ratio(s): 54.5:1
Front axle/differential: Dana 44/3.54 gears, open
Rear axle/differential: Dana 60/3.54 gears, open

Suspension
Front: 6-in-lift Superlift coil springs, Les Schwab shocks
Rear: 6-in-lift Deaver leaf springs, Les Schwab shocks
Steering: Stock w/Skyjacker 6-in-drop pitman arm

Wheels/Tires
Tires: LT37x12.50R15 Goodyear MT/R
Wheels: 15x10 aluminum w/TrailReady beadlock (front), 15x10 steel (rear)

Miscellaneous
Armor: Custom front bumper and nerf bars
Cool stuff: Warn 8274 winch

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