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Ford Bronco Lift Page

 

 


Lifting

 

How much to lift a truck and what size tire will fit is probably the biggest question for those in the 4x4 community.  What is often overlooked is how a particular setup will perform on and off the road and what one really needs vs. thinks one wants.

 

To a point larger and more aggressive tires will increase offroad performance.  But if your drive train, gearing, braking and steering aren't adequate for the tires you choose to run, you'll loose any advantage of larger tires in the offroad environment to a decrease in power, breakage and inability to safely steer or stop.  This point is generally mute, as most people will run larger tires for the sole purpose of having a more aggressive image while driving to work.

 

Why a lift?

 

Downside of lifting a truck

 

What size do you need?  This is a very subjective question indeed.

 

 


Non Lift Options

 

Lifting a truck has a lot of detrimental affects.  It causes an increase in the center of gravity, geometry changes in steering, suspension arc and driveline angles are affected in some form, and aerodynamics will likely to be adversely affected.  Some lifting techniques are downright dangerous and complete lift systems/modifications can easily total up into the thousands of dollars once completed.

 

Here are a few options:

 

Don't modify it

A Ford Bronco can fit 33 x 12.50 tires on 7.5" rims without mod.  This tire size is sufficient for most offroad use.

 

Body lifts

Body lifts raise the body above the frame which causes less of an increase in the center of gravity than a suspension lift and don't alter steering and driveline angles.  For those going for that American offroad look and don't care about offroad performance - a body lift might be a less damaging way to go.  A body lift in some vehicles may allow for raising the drive train and allowing for a flat skid plate to be mounted flush with the frame.

 

Fiberglass Body Panels

There are several companies that make fiberglass panels and one piece front ends with enlarged wheel wells.  These body part alone or in conjunction with suspension modifications will allow for larger tires without body/tire contact when the suspension or steering articulates. 

 

Some of these panels are made to be bolt on replacements while others are flimsier race weight versions that may not last the life of your truck.  Fiberglass panels can be Rhino Lined on the underside (or even the outside) for reinforcement. Try Autofab, McNeil Racing, Baja Concepts and Giant Motorsports.

 

Cut Out Fenders

If you just want to go with bigger tires, why not just trim your fenders?  The answer is obvious - it will look terrible.  Cut out fenders often do look terrible, but they don't have to.  If you carefully plan your new opening, you can mark it, trim off the rolled in edge, cut perpendicular to the new edge at intervals, use pliers and a hammer to reshape them, rivet a backing plate for strength, paint and consider using rubber fender flares with a finishing lip to cover up any imperfections.  Even armatures can touch up cuts with Bondo and have a decent looking end product.  And if you have metal working or fiberglass skills, you can do all kinds of things.

 

 

Even if you do a lift, trimming your fenders is still a great idea since it will allow you to use that extra travel without damaging your body and tire.

 

Artic Truck Nissan Patrol with 44" tires

 

There are a few companies that can do plastic or fiberglass flares for cut out fenders.  The disadvantage of these flares is that they can be damaged by trees and rocks, and may need to be replaced or repaired - perhaps not a big issue in Iceland where they are quite popular.  Flares can also be Rhino-Lined inside and out for more durability.

 

 

The only big name for cutout fender flares in the US is Bushwacker.  According to their installation instructions (87-91 without a lift), their cutout flares will accommodate:

Wheel 8 or 10 wide with 3 back spacing
Tire Radial type (rounded shoulder)

a) Stock front bumper stock position 33/8 rim
b) Stock front bumper moved forward 2 35/10 rim
c) Aftermarket tube bumper that does not wrap around into wheel well opening 37/10 or 12 rim.

 

 

There are several fiberglass shops in Iceland that make boats, Jacuzzis and cut-out fender flares.  Artic Trucks in Iceland are know for their large fender flares and wheel well openings and have custom flares for all kinds of vehicles.  Also take a look at these sites for some ideas.

http://www.jeppaplast.is/?a=4

http://www.offroad.no/?Page=Rig

http://www.brettakantar.is/?pid=myndir&iUndir=20

http://formverk.is/

http://samtak.is/Fender%20flares.htm

http://www.4x4offroads.com/truck-fender-flare.html

 

 

Compare the following stock Bronco with the lifted Icelandic Bronco with cutout fenders.  The cutout fenders allow for fitting of huge tires without tire fender contact, and allows of fitting of significantly larger tires than stock without a lift.

 

Stock Bronco

 

Lifted Bronco with Cutout Fenders and Custom Flares

Note: Axles have also been replaced and relocated

 

Superimposed images to show fender area removed

 

 


Suspension Lift Options


Front Lift

 

 

 

 


 

Various race-ready options with these kits include extended shock bracket and/or coil-over springs.

 

 


Rear lift

 


What Axles do I need?

Front

 

 

Reverse Shackle Kit

 

 

Fabritech Bronco

 

 

 

 

Note - if you need to convert your TTB Dana 44 front to an 8-lug configuration - use Dana 44 parts from a 10 bolt 3/4 ton axle from an early '70's Chevy K20 4x4.

 

Rear

 

More detailed info on 80-96 Bronco lift and tire options can be found at http://www.fullsizebronco.com/forum/showthread.php?t=17022&page=1&pp=20

 

 


Subjective Axle Strength

 

 

Max tire Size

Common Failures

Corporate 20

32in

Tubes twist, flange hubs spin, Seals leak, very weak axles

Dana 27

31in

Weak axles, housing breaks

Dana 28 ifs

31in

spindle and wheel bearing failure

Dana 30

32in

tubes and knuckles bend, spider gears

Dana 35

32in

tubes bend, diff bearings wear quick

Dana 35 ifs

33in

wheel bearings, outer axle failure

Dana 44

36in

early small axles break, floater kits break axles if housing isn't straight when installed

Dana 44 ifs

33in

R&P weak, hubs and half shafts

Dana 60

44in

in pickups carrier bearings fail

GM10 Bolt

33in

carriers break, tubes bend, weak axles, spider gears, outer wheel bearings

GM 12 Bolt

36in

tubes bend, pinion bearings wear, spider gears, wheel bearings, axles

GM 14 Bolt 10.5"

44in

Gov-loks fail

Ford 8.8

33in

stock axles, spider gears

Ford 9 in

38in

Early 28 spline axles weak

Ford 10.25in

44in

similar in strength to Dana 70 and 14 Bolt Full Floater

 

Axle Shaft strength varies greatly with design, material and application

 Spline

Count

Torque

Applications

23

1573

Samurai Front

24

2241

 

25

2909

 

26

3576

Samurai Rear

27

4244

Dana 30 and 35

28

4912

10 Bolt (pre 90)

29

5580

AMC 20

30

6248

Dana 44, 50, and 60 (LD)

Toyota

10 and 12 Bolt

31

6915

Ford 8.8", 9"

32

7583

 

33

8251

14 Bolt (9.5")

34

8919

 

35

9586

Dana 60 (HD), 70

14 Bolt (10.5")

Ford 10.25"

36

10254

 

37

10922

 

38

11590

 

39

12258

 

40

12925

 

 

Axle (most)

Shaft Diameter
(at splines)

Spline Count

Ring Gear
Diameter

Model 20

1.25"

29

8.875"

Dana 30

1.16"

27

7.2"

Dana 35c

1.16"

27

7.5"

Superior
Dana 35c

1.31"

30

7.5"

Dana 44

1.31"

30

8.5"

Dana 50

80 - 02

1.31"

30

9"

10-bolt

1.20"

28

8.5"

10-bolt

1.31"

30

8.5"

12-bolt

1.31"

30

8.5"

14-bolt

1.285"

30

9.5"

14-bolt SF

1.37"

33

9.5"

14-bolt FF

1.50"

35

10.5"

Ford 8.8

front 97 on

1.2"

28

8.8"

Ford 8.8

Rear 83 on

1.32"

31

8.8"

Ford 9"

1.19"

28

9"

Ford 9"

76 - 86

1.32"

31

9"

Ford 10.25"

1.50"

35

10.25"

Dana 60 FF

F250 81 - 84
F250 75 - 79

F350 78 - 79

1.31"

30

9.75"

Dana 60 SF

E250 Van 81 On

F250 80-85

1.50"

35

9.75"

Dana 60 FF

95 - 96

1.41"

32

9.75"

Dana 60

1.50"

35

9.75"

Dana 70

F250 02 On

1.41"

32

 

Dana 70HD

F350 75 - 85

1.50"

35

10.5"

 

Outers

Axle (most)

Shaft Diameter
(shaft to splines)

Spline Count

Dana 44

1.060"-1.155"

19

Dana 60

1.250"-1.3125"

30

Dana 70

1.375"-1.50"

35

 

STRENGTH COMPARISON OF COMMON O.E. AUTOMOTIVE & RACING SPLINES

# Teeth

Pressure Angle

Common Application

Major Diameter

Minor Diameter

% Change in Diameter

% Change in Strength

             

28

30 deg

GM Buick & Pontiac '64-'70 Axle

1.1960

1.127

-7.9%

-21.9%

30

30 deg

8-3/4" Mopar '57-'64

1.2793

1.1960

-1.0%

-3.0%

31

30 deg

Olds/Pontiac '57-'64

1.3210

1.2377

2.4%

7.5%

35

30 deg

Dana 60 Strange & Lenco spools

1.4876

1.4043

16.2%

57.0%

             

26

45 deg

GM 10 bolt 7-1/2" '82 & later

1.1250

1.0417

-13.8%

-35.9%

28

45 deg

GM 10 bolt 8.5" & 8.2" '65-'81 & Ford 9" & 8.8"

1.2083

1.1250

-6.9%

-19.3%

31

45 deg

9" Ford

1.3333

1.2500

3.5%

10.7%

33

45 deg

Strange 9" Ford spools

1.4167

1.3333

10.3%

34.4%

35

45 deg

Mark Williams 35 Spline spools

1.5000

1.4167

17.2%

61.2%

40

45 deg

Mark Williams 9" Dana 60 Spools

1.7083

1.6250

34.5%

143.2%

 

Axle Catalog


Solid Axle Swaps

Copied from Miesk5

SAS, Questionnaire at FSB Forums fullsizebronco.com

SAS on an 80 by Tim F (Timmy, TIM-MAY) at SuperFord.org

SAS on an 80 by Ryan P at SuperFord.org

SAS on an 81 by Larry S (The Bronc, Larston, Lars915, Lars geocities site)

SAS on an 81 by Larry S (The Bronc, Larston, Lars915, Lars earthlink site) - web site is gone, but this is a Cached version via web.archive.org

SAS on an 81 by Larry S (The Bronc, Larston, Lars915, Lars SuperFord site) 

SAS on an 81 pics by Bryan (BigB, Pile_Of_Parts, The Black Beast) at SuperFord.org

SAS & track bar pics on an 81 by 81yellowbronco (Eddie, Big bird) at sounddomain.com

SAS on an 82 by Daryl P (The Bronc) at SuperFord.org

SAS on an 83 pics by Adam D (flip) at SuperFord.org

SAS on an 83 pics by John B (nu bronco, nu_bronco) at SuperFord.org 

SAS on an 84 by Joe Y (Excursion, 84excursion) at SuperFord.org

SAS on an 85 by Chris B (Blue) at SuperFord.org

SAS on an 85 by Chris C (Chris85xlt, Erika) at SuperFord.org

SAS on an 85 by Larry H at SuperFord.org

SAS on an 85 by Bronco85 (Phillip H, Big Red) at FSB Forums  fullsizebronco.com

SAS on an 85 by Bronco85 (Phillip H, Big Red) at SuperFord.org

SAS on an 86 by BigNorm (Old Desert Goat) at FSB Forums fullsizebronco.com

SAS on an 86 by BigNorm (Old Desert Goat) at SuperFord.org

SAS on an 88 by Arin at SuperFord.org

SAS on an 88 pic by Brandon l at SuperFord.org

SAS on an 88 pic by Jeff R at SuperFord.org

SAS on an 88 by ColoradoBronc at SuperFord.org 

SAS on an 89 by Stomper4x4 at FSB Forums fullsizebronco.com

SAS on an 89 by Stomper4x4 at SuperFord.org

SAS on a 90 by Ryan K at Broncotech.com

SAS on a 90 by Dan K at SuperFord.org

SAS pics on a 90 by Alan T at SuperFord.org

SAS on a 91 by Mark H (welndmn, Wheeling Demon) & David B (dblue, One Ton 91', Centurion) at wt4x4.net

SAS on a 92 by Jeremy M (Big '92, jermil01) at SuperFord.org

SAS on a 92 by Jeremy M (Big '92, jermil01) at FSB Forums fullsizebronco.com

SAS on a 92 pics by jimmy d (the bronc) at SuperFord.org

SAS on a 92 by Kuss (Todd, kusscave) at kusscave.com

SAS w/Dynatrac ProRock Dana 60 on a 92 by Kuss (SuperFord site, Todd, kusscave) at SuperFord.org

SAS on a 93 by Dustin J (rokhrse, sukngas) at SuperFord.org

SAS on a 93 by Brian G (crackhead) at thewanderinggilberts.com

SAS on a 93 by Brian G (crackhead) at SuperFord.org

SAS on a 92+ (Shane) via Pepper (Big Pig) at SuperFord.org 

SAS on a 93 by FlaMudslinger at SuperFord.org

SAS on a 94 by Damon H (Plug Ugly) at SuperFord.org

SAS on a 94 by Scott S (Canyonaro, dogonmut) at SuperFord.org

SAS on a 94 by Haustkraft (Rob, The Green Macheen) at FSB Forums fullsizebronco.com

SAS on a 94 by Haustkraft (Rob, The Green Macheen) at SuperFord.org

SAS on a 94 by da94broncodude (Joey L, Joeys) at Ford Truck World

SAS, part 2 on a 94 by Haustkraft (Rob, The Green Macheen) at FSB Forums fullsizebronco.com 

SAS pics on a 94 by Scott S (dogonmut, Canyonaro) at FSB Forums fullsizebronco.com

SAS #2 w/springs pics on a 94 by Scott S (Canyonaro, dogonmut) at FSB Forums fullsizebronco.com

SAS #2 w/springs pics on a 94 by Scott S (Canyonaro, dogonmut) at SuperFord.org

SAS on a 94 by Broncosorus (Gerard, 94bronco351) at fordtruckworld.com

SAS on a 94 by Alan M (Pimp Wagon) at Ford Truck World

SAS on a 94 by Blaze (Broncosaurus) at SuperFord.org

SAS on a 94 by Haustkraft (Eleanor, Rob, The Green Macheen) at FSB Forums fullsizebronco.com

SAS on a 94 by Haustkraft (Eleanor, Rob, The Green Macheen) at SuperFord.org

SAS on 80-96 by Fabritech via broncograveyard.com

SAS on a 95 by Pepper (Big Pig) at SuperFord.org

SAS on a 95 by Derik H (95bronc, mudbronco) at SuperFord.org

SAS pics on a 95 by Derik H (95bronc, mudbronco) at brinkster.com

SAS on a 95 by Rafael E (Bronkzilla) at SuperFord.org

SAS on a 95 by InkDawg at SuperFord.org

SAS re-done on a 95 by Biggie_Truck (Project X) at SuperFord.org

SAS on a 95 by kd5kuu (Ben S) at FSB Forums  fullsizebronco.com

SAS on a 95 by TheJuice (The Juice, Mark Z) at SuperFord.org

SAS pics on a 95 by kd5kuu (Ben S) at SuperFord.org

SAS w/Dana 60/leaf springs on a 95 by JoeBob1901 (Joseph B) at SuperFord.org

SAS on a 96 by Scott L (IH8Jeeps) at SuperFord.org

SAS pic on a 96 by bigbronco1996 (Patrick G) at SuperFord.org

SAS pics for Jer by Pepper (Big Pig) at SuperFord.org

SAS Cost Discussion at FSB Forums fullsizebronco.com

SAS Information & Parts List by Jeremy M (Big '92, jermil01) at FSB Forums fullsizebronco.com

SAS Parts for a 90 by Chris S (Blown, CLYDE) at SuperFord.org

SAS Parts List for an 85 by Chris B (Blue) at chrisb.users.SuperFord.org

SAS Parts List for a 92 by Jeremy M (Big '92, jermil01) at SuperFord.org

SAS Parts Cost & Sources on a 92 by Jeremy M (Big '92 jermil01) at SuperFord.org 

 


Shackle Flips

Copied from Miesk5

Shackle Flip on a 78 by Tracy (Stinger) at SuperFord.org

Shackle Flip (Sky) on a 78 by Jon S (RaisedIIPerfection, Blazer Assault Vehicle) at SuperFord.org

Shackle Flip pic on a 78 by Ken M at SuperFord.org

Shackle Flip (Sky) on an 83 by John B (nu bronco, nu_bronco) at SuperFord.org

Shackle Flip (Sky) on an 83 by Michael C (collinsperformance, The Money Monster) at SuperFord.org

Shackle Flip (Sky) on an 85 by Bronco85 (Phillip H, Big Red) at SuperFord.org

Shackle Flip (Sky) on an 85 by Bronco85 (Phillip H, Big Red) at FSBForums  fullsizebronco.com

Shackle Flip, pics on an 85 by Dan K (Big Bird) at SuperFord.org

Shackle Flip on an 86 by BigNorm (Old Desert Goat) at SuperFord.org

Shackle Flip (F 450) pic on an 86 by John B (Swamp Donkey) at SuperFord.org

Shackle Flip, w/measurements on an 87 by Joey S (Nacho, Stokes, Larry, Stoked) at SuperFord.org

Shackle Flip on an 88 by Chris G at 2bigbroncos.org

Shackle Flip on an 88 by Arin at SuperFord.org

Shackle Flip on an 88 by bAdKARma88 (Perry T, Bad Karma) at SuperFord.org

Shackle Flip (Sky) on an 88 by Ironclad (Jeff J, da Money Pit) at FSB Forums fullsizebronco.com

Shackle Flip (Sky) on an 88 by Ironclad (Jeff J, da Money Pit) at SuperFord.org

Shackle Flip on an 89 by Will H (kf4amu, The Beast) at SuperFord.org

Shackle Flip (Sky) on an 89 by southrnpride69 at SuperFord.org

Shackle Flip (Sky) on an 89 by southrnpride69 at FSB Forums fullsizebronco.com

Shackle Flip on a 90 by Chris S (Blown, CLYDE) at SuperFord.org

Shackle Flip on a 90 by Keith L (TTB Blows, Bling-Bling) at SuperFord.org

Shackle Flip on a 90 by Shawn C (El Trucke Trucke) at SuperFord.org

Shackle Flip on a 90 by Lance D (4BY4PLA) at SuperFord.org

Shackle Flip (Sky) on a 90 by Alan T at SuperFord.org

Shackle Flip on a 91 by Meixter (Cookie Monster) at SuperFord.org

Shackle Flip (Sky) on a 92 by Tank92 (Tank) at FSB Forums fullsizebronco.com

Shackle Flip (Sky) on a 92 by Tank92 (Tank) at SuperFord.org

Shackle Flip (Sky) on a 93 by Froggmann (Ken P) at froggmann.com

Shackle Flip on a 93 by Muddybronco (Eric) at arkansasmud.com

Shackle Flip on a 93 by 2bitbronco (nobs) at SuperFord.org

Shackle Flip on a 93 by Brian G (crackhead) at SuperFord.org

Shackle Flip (Sky) on a 94 by Alan M (Pimp Wagon) at Ford Truck World

Shackle Flip on a 94 by Damon H (Plug Ugly) at SuperFord.org

Shackle Flip on a 95 by JoeBob1901 (Joseph B) at SuperFord.org

Shackle Flip Kit, Sky pic on a 90 by 90Beater (Topher, Chris) at bronco.tophersworld.com

 


Quick Converter

P-Metric Style

Example: 215/75R15
/ R



Inch Style

Example: 31 x 10.50 x 15
x x

 


Future reference:

Height:

No top, 37.5" GYMT: 7'

No top with lights, 37.5" GYMT: 7' 6"

 

 


 

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