Gary's Garagemahal (the Bullnose bible)
  • Bullnose Forum
    • Guidelines
    • Ford Truck Show
    • Forum FAQ's
    • Member's Map
    • Forum & Website Issues
    • Test Forum
    • Smilies
  • Documentation
    • Accessories >
      • Air Horns
      • CB Radio
      • Roll Bar
      • Step
      • Tie Down Hooks
      • Tonneau Cover
    • Body >
      • Bronco Rear Window
      • Body Shell, Exterior Trim, Frame & Underbody
      • Door Latches & Locks
      • Door Hinges Checks & Weatherstrips
      • Doors Hood & Tailgate General Service
      • Front Door Window Glass & Mechanisms
      • Hood & Hinges
      • Hood Latch
      • Lock Cylinders & Keys
      • Power Door Locks
      • Power Windows
      • Stationary Glass - Butyl Seal
      • Stationary Glass - Weatherstrip Seal
      • Tailgate
      • Vent Window Mechanism
      • Window Glass & Mechanisms - General Service
    • Bullnose FAQ's
    • Bullnose Upgrades
    • Calibration Info & Part #'s
    • Cooling Systems >
      • Cooling Fan #'s & Illustrations
      • Cooling System Illustrations
      • Coolant Recovery & Windshield Washer Reservoirs
      • Elbows
      • Heater Hoses
      • Hose Clamps
      • Radiator Hoses
      • Radiator Support
      • Radiator Part #'s
      • Shroud Part #'s
      • Thermostats
      • Water Pump #'s & Illustrations
    • Driveline >
      • 4WD Front Hubs & Rotors
      • Axles & Differentials
      • Bell Housings
      • Brakes
      • Calculators
      • Clutches and Linkage
      • Drive Shafts
      • Engine Plates
      • Rear Axle Vents
      • Skid Plates
      • Transfer Cases
      • Transmissions >
        • Transmission & Transfer Case Ratios
        • Automatic Transmission >
          • Automatic Transmission Applications
          • General Automatic Transmission Service
          • Automatic Overdrive (AOD)
          • C6
          • Kickdown Linkage
          • Neutral Start Switch
        • Manual Transmissions >
          • Manual Transmission Applications
          • General Manual Transmission Service
          • 3.03 3-Speed Toploader
          • NP435
          • Single Rail Over Drive (SROD)
          • TOD & SROD Transmissions
          • TOD
          • Warner T-18 & T-19
          • ZF5
        • Over/Under Drives
      • Speedometer Gears, Cables, & Sensors
      • Wheels & Tires
      • Wheel Covers
    • Electrical >
      • 3G Conversion >
        • 3G Conversion - In Development
        • 3G Writeup From Lucas
      • Alternators
      • Ammeter
      • Batteries
      • Battery Cables
      • Battery Trays
      • Circuit Protection
      • Clocks
      • Computer Internals
      • Connectors
      • Distributors
      • Electrical Connectors
      • Electronic Engine Control (EEC)
      • Electricity 099
      • EVTM >
        • 1980 EVTM
        • 1981 EVTM
        • 1985 EVTM
        • 1986 EVTM
        • 1996 EVTM >
          • Index
          • Charging System
          • Daytime Running Lamps
          • Engine Control - 4.9L
          • Engine Control - 5.0L
          • Engine Control - 5.8L Under 8500 GVW
          • Engine Control - 5.8L Over 8500 & 7.5L EEC-IV
          • Engine Control - 7.5L EEC-V
          • Engine Control - Turbo Diesel
          • Fuse Panel & Circuit Protection
          • Grounds
          • How To Use This Manual
          • Ignition System
          • Keyless Entry
          • Power Distribution
          • Speed Control
          • Starting System
          • Transmission Control - 4R70W
          • Transmission Control - E4OD
      • Gauges
      • Ground Wires >
        • Engine-to-Firewall Ground
        • Battery to Ground
        • Battery to RH Fender
        • Firewall to Hood
      • ICVR
      • Ignition
      • Lighting >
        • Dome and Cargo Lights
        • Fog or Driving Lights
        • Headlight Wiring Harness
        • Lighting & Calculations
        • Tag Lights
      • PMGR Starter Wiring
      • Radios
      • Relays
      • Sending Units
      • Speed Control
      • Standard Wire And Color Codes
      • Switches
      • Tachometers
      • Terminals & Connectors
      • Voltage Drop Testing
      • Windshield Wipers
      • Wiring Connectors
      • Wiring Diagrams
      • Wiring Harnesses
      • Wire Routing
    • Emissions >
      • Understanding Emissions Controls
      • Inferred Mileage
      • Thermactor Systems
    • Engines >
      • Compression Ratio Calculator
      • General Engine Service
      • 3.8L (232) V6
      • 300 Six
      • Windsor Series
      • 351M and 400
      • 385 Series
      • IDI Diesel
      • Drive Belts
      • EGR Valves >
        • EGR System Description & Testing
        • EGR Spacer
        • Gasket: Carb/EGR to Intake (9447)
      • Flywheels
      • Manifolds, EGR, Heat Valves, etc
      • Engine Swaps >
        • 300 Six to Small-Block V8
      • Pulleys
      • Starters
    • Exhaust Systems
    • Exterior >
      • Beds, Tailgates, and Components
      • Bumpers
      • Exterior Mirrors
      • Exterior Moulding Retainers
      • Exterior Trim and Moulding
      • Frames >
        • Engine Perches
      • Fuel Filler Doors
      • Name Plates
      • Push Bars
      • Spare Tire Carriers
      • Stationary Glass - Butyl Type Seal
      • Tape And Decal Application
    • Fasteners & Illustrations >
      • Fastener Pictures
      • Fenders and Aprons
      • Frame
      • Headlights and Turn Signals
      • Hood
      • Radiator and Grille
    • Fuel & Air Systems >
      • 1985-1986 Fuel System Adjustments
      • 460 Fuel Systems
      • Air Cleaners
      • Carburetors, Chokes, & EFI >
        • EFI Idle Speed Adjustment
        • Jetting
        • How To Find Carb Parts
        • Chokes
        • Carter YFA 1bbl
        • EFI
        • Edelbrock
        • Motorcraft 2150
        • Holley 4180C
        • Motorcraft 7200 VV
      • Correct Cold Starting Procedures
      • Diagnostics
      • Fuel System Illustrations >
        • Fuel Filler Pipes
        • 1980-84 F-Series & Bronco
        • 1983-84 F-Series Diesel
        • 1983-87 F350 Chassis Cab DRW
        • 1985 F-Series 302 w/EFI
        • 1985-87 Bronco
        • 1985 on F-Series
      • Fuel System Part #'s >
        • Fuel Filler Pipes
        • Fuel Senders & Pumps
        • Fuel Tanks
        • Fuel Tank Selector Switch
        • Fuel Tank Selector Valve
        • Fuel Tank Shields
        • Fuel Vapor Valve
        • Fuel Vapor Separator
      • Fuel System Wiring
    • HVAC >
      • Blend Door Repair
      • HVAC Systems
      • 300 Six Compressor Illustrations
      • Factory A/C Brackets
    • Interchange >
      • Air Conditioning Interchange
      • Alternator Interchange
      • Brake Interchange
      • Carburetor Interchange
      • Crankshaft Interchange
      • Diesel Injector Pump Interchange
      • Distributor Interchange
      • Fuel Pump Interchange
      • Head Interchange
      • Starter Interchange
      • Steering Interchange
      • Window Lift Motor Interchange
      • Water Pump Interchange
    • Interior >
      • Behind The Seat Storage
      • Boots
      • Carpet
      • Dash
      • Doors >
        • Door Locks
        • Door Panels
        • Electric Windows & Locks
        • Handles & Boot
        • Vent Windows
        • Windows
      • Horn Pads
      • Insulation
      • Interior Soft Trim
      • Interior Trim
      • Instrument Panel Name Plates
      • Instrument & Radio Bezels
      • Kick Panels
      • Knobs
      • Painting Gauge Needles
      • Rear Corner Trim
      • Rear View Mirror
      • Salvaging Rosewood
      • Seat Belts
      • Seat Interchangeability
      • Seats & Seat Tracks
      • Sill Plates
      • Steering Columns & Steering Wheels
      • Sun Visors
    • Picture Galleries >
      • 1981 F100 With 318 Miles
      • 1983 XLS Survivor
      • 1983 Ford Bronco 4x4 Dobbs-Stroppe Team Chase Car
      • 1983 Bronco Survivor
      • 1984 Bronco XLT
      • 1984 F150 XL
      • 1984 F150 Survivor
      • 1984 FORD F-150 XLT PICKUP
      • 1985 F-150 Survivor
      • 1985 F150 4×4 Flareside
      • Big Blackie
      • Big Blue >
        • Big Blues Documentation
      • Dad's Truck >
        • Air Cleaner
        • Aluminum Wheel Refinishing
        • Electrical Components >
          • Alternator
          • Battery
          • Power Distribution
        • Gauges
        • Engine
        • Frame
        • Seats
        • Transfer Case
        • Transmission
      • Rusty
    • Reference >
      • Hose & Fittings
      • Standard & Utility Parts Catalog
    • Specifications >
      • Assembly Plants
      • Axle Ratios
      • Body Codes - Interior
      • Build Sheet Interpretation
      • Dimensions and Weights
      • Interior Paint
      • Calibration Codes
      • Certification Label
      • DSO Codes
      • Electrical
      • Engine Codes
      • Exterior Paint Codes
      • 10-01 Identification Codes
      • Lubricant Specifications
      • Model Codes
      • Spring Codes
      • Standard Features And Options
      • Towing
      • Transmission Codes
      • Tape Stripe Codes >
        • Bronco Tape Stripe Codes
        • F-Series Tape Stripe Codes
      • VIN Decoding
    • Suspension & Steering >
      • 2WD Spindles
      • Alignment
      • Body Mounts
      • Crossmembers
      • Front Suspension
      • Steering >
        • General Steering Service
        • Coupling - Rag Joint
        • Manual Steering Gear Box
        • Power Steering
        • Saginaw Conversions
        • Steering Columns
        • Tie Rods and Drag Links
      • Rear Suspension >
        • Auxiliary Springs
        • Rear Springs
      • Sway Bar
    • TSB's >
      • TSB Index
      • TSB Bulletin List
      • Body/Windnoise/Water Leaks/Trim >
        • 81-06-13 Bumper Guard & Tire Carrier
        • 81-7-23 Seat Belts Become Too Tight
        • 83-3-15 Pickup Box Alignment
        • 81-06-15 Pickup Box Wood Floor Replacement
        • 83-13-4 Sheet Metal Welding Procedures
        • 83-16-17 Pickup Box Lean
        • 83-24-18 Swing-Lock Mirror Moves
        • 83-13-22 Electric Mirror Loose Glass
        • 83-24-19 Mirror Head Vibration
        • 87-01-18 Tool Box Mount
      • Electrical / Climate Control / Starting / Charging >
        • 80-4-13S A/C RAPID ON-OFF CYCLING OF COMPRESSOR CLUTCH
        • 81-1-10 FM Radio Interference
        • 81-7-24 Temperature Control Cable Too Long
        • 84-24-9 Noise - Radio Ignition Buzz
        • 87-03-07 EEC-IV Driveability TSB Summary
        • 87-07-20 Radio Ignition Noise
        • 87-21-10 EEC-IV Diagnostics
        • 88-05-07 Malfunction Indicator Light Introduction
        • 89-22-08 Emissions Maintenance Warning Module
        • 90-25-12 Speed Control
        • 96-21-04 2G Alternator Repair
      • Brakes/Steering/Suspension/Wheels >
        • 80-14-14-S STEERING
        • 81-06-04 Integral Power Steering Gear
        • 81-06-16 Front Wheel Grease Seal Gaskets
        • 81-06-17 Rear Parking Brake Cables
        • 81-2-25 REAR SUSPENSION TORQUE SPECS
        • 89-19-01 Brake Noise Recap Of TSB's
        • 89-25-16 Brake Ride Height Proportioning Valve
        • 90-13-9 Frame Cracking At Rear Shock Mount
        • 96-15-11 Frame-Rivet Replacement With Bolts
        • 97-03-10 Frame Creaking/Popping
        • Steering Gear Frame Liner
      • Engine/Cooling System/Exhaust >
        • 81-2-27 ENGINE DETONATION
        • 83-13-7 Correct Oil Fill Level
        • 83-25-21 Air Cleaner Sealing
        • 83-13-8 RTV Sealant - New Material
        • 87-06-10 Stall/No Start: TFI
        • 88-07-16 4.9L Exhaust Manifold Warping
      • Transmission/Clutch/Driveshaft/Axle >
        • 81-5-15 AOD TRANSMISSION
        • 81-06-18 Clutch Housing Fills w/Mud/Dirt
        • 81-07-25 Clutch Shudder/Chatter In Reverse
        • 81-7-26 Missing Shims On SROD
        • 82-25-16(S) Upshift Indicator Light
        • 83-3-23 Axle Lubricant Drain And Refill
        • 83-23-17 8.8" Rear Axle Vent
        • 84-24-13 Transfer Case - Grinding/Block-Out
        • 90-16-07 High Clutch Effort
      • Driveability/Fuel/Ignition/Emissions >
        • 81-6-19 Cold Driveaway Performance Improvements
        • 81-6-20 Piston Slap During Cold Driveaway
        • 81-6-21 Power Valve Vacuum Hose
        • 83-11-12-S Stall/No Start/Hessitation
        • 88-05-14 Low Oil Pressure
        • 91-25-07 IAC Bypass
        • EMW Module
      • Noise/Vibration/Ride/Squeaks/Rattles >
        • 80-1-12-S REAR SPRING SQUEAK
      • Miscellaneous/General >
        • 83-14-1 UNDERHOOD PRODUCTION STAMP RELOCATION
      • Health/Safety/Environmental Hazard information
      • CALIBRATION: 4-53F-R00
      • Fuel Cross-Flow
    • Underhood >
      • Cowl Seal
      • Engine Compartment Lamp
      • Fender Aprons
      • Jacks, Lug Wrenches, etc
      • Speed Control
      • Tool Box
    • Vacuum Systems >
      • Vacuum System Acronyms
      • Vacuum Diagrams >
        • 300 Six
        • 302/5.0L
        • 351W
        • 351M/400
        • 460 V8
      • Vacuum Fittings
      • Vacuum Reservoirs
      • Vacuum System Requirements
      • Vacuum System Testing
    • Metrics
    • About Me/Contact Me >
      • Youth Classes >
        • Automotive Maintenance >
          • Fall of 2015
        • Building Web Sites >
          • Lesson 1
          • Lesson 2
          • Lesson 3
          • LTC
        • Overview of Paul's Life, Journeys, & Works >
          • Lesson 1
          • Lesson 2
      • Projects >
        • Engine Cradle
        • Gauge Pocket
        • Rear Bumper And Spare Tire Carrier
    • Year-To-Year Differences >
      • Door Locks & Turn Signals
    • Test Page
    • 91-6-7 Sterling 10.25 Hub Leaks
  • Manuals & Literature
  • About
  • Truck Shows
    • 2020 Truck Show >
      • Entrant #1: Dad's Truck
      • Entrant #2: Big Blue
      • Entrant #3: Tommy Sides 1986 F150
      • Entrant #4: Darth/Bill Vose
      • Entrant #5: Sam Noller's 1985 Bronco
      • Entrant #6: Mein Laster
      • Entrant #7: Andre's Bronco
      • Entrant #8: Chad's Rosebud
      • Entrant #9: Matthew’s Truck of Doom
      • Entrant #10: Ron's Flareside
      • Entrant #11: Cory's Blue Mule
      • Entrant #12: Ratdude747'S 1984 F150
      • Entrant #13: Ratdude747's '95 Ranger
      • Entrant #14: Heinz' 1986 F150
      • Entrant #15: Anna's Toy
      • Entrant #16: Frank's 1981 F-150 Custom
      • Entrant # 17: Petes 1981 F150 Flareside
      • Entrant #18: Eric's F250 XLT Lariat
      • Entrant #19: Geejaypea's Georgian Hulk
      • Entrant #20: JohnnyBronco85's Bronco
      • Entrant #21: Skaeke's 1985 F150 Lariat
      • Entrant #22: Sam1982's F100
      • Entrant #23: NostraDanus' 1986 Bronco
      • Entrant #24: MarkF100's F100
      • Entrant #25: Bruce moose4x4's 1996 Bronco
      • Entrant #26: Bruce Mooose4x4's 1995 F150
      • Entrant #27: Troy/66gtk's 1983 F150 XL SWB 4x2
      • Entrant #28: Matt Wood's 1985 Bronco
      • Entrant #29: WelderScott's '78 F150
      • Entrant #30: Mehmetcelikel's Brownie Dually
      • Entrant #31: Kristopherdb's 1985 Flairside 4x4
      • Entrant #32: Clifton's Tessa
      • Entrant #33: BinFord's Beverly
      • Entrant #34: BinFord's Crackling Rosie
      • Entrant #35: Dan aka dblohowiak's 1986 F250HD
      • Entrant #36: Jonathan's 1981 F150
      • Entrant #37: Jonathan's 1995 F Superduty
      • Entrant #38: Jonathan's 1986 F350 short bed crew cab IDI
      • Entrant #39: Brian's 1986 F250
      • Entrant #40: Jay's 1986 F150
      • Entrant #41: Eddie's 1981 F100 Custom
      • Entrant #42: Nick & George's Brutus
      • Entrant #43: Matthew's 1983 F350
      • Entrant #44: Hogie's 81 F250
      • Entrant #45: TontoKowalski's 1985 F150
      • Entrant #46: Danny's 1982 Bronco
      • Entrant #47: Greg's 1980 F150 Ranger XLT
      • Entrant #48: Chris' 1982 XLS
      • Entrant #49: Chris' 1985 Bronco
      • Entrant #50: Ken & Kathy's 1977 F250
      • Entrant #51: Ken & Kathy's 1985 Flareside
      • Entrant #52: Kevin/Teach's F250 Lariat
    • 2021 Truck Show
    • 2022 Truck Show
  • New Bullnose Test Forum
  • Bullnose Forum
    • Guidelines
    • Ford Truck Show
    • Forum FAQ's
    • Member's Map
    • Forum & Website Issues
    • Test Forum
    • Smilies
  • Documentation
    • Accessories >
      • Air Horns
      • CB Radio
      • Roll Bar
      • Step
      • Tie Down Hooks
      • Tonneau Cover
    • Body >
      • Bronco Rear Window
      • Body Shell, Exterior Trim, Frame & Underbody
      • Door Latches & Locks
      • Door Hinges Checks & Weatherstrips
      • Doors Hood & Tailgate General Service
      • Front Door Window Glass & Mechanisms
      • Hood & Hinges
      • Hood Latch
      • Lock Cylinders & Keys
      • Power Door Locks
      • Power Windows
      • Stationary Glass - Butyl Seal
      • Stationary Glass - Weatherstrip Seal
      • Tailgate
      • Vent Window Mechanism
      • Window Glass & Mechanisms - General Service
    • Bullnose FAQ's
    • Bullnose Upgrades
    • Calibration Info & Part #'s
    • Cooling Systems >
      • Cooling Fan #'s & Illustrations
      • Cooling System Illustrations
      • Coolant Recovery & Windshield Washer Reservoirs
      • Elbows
      • Heater Hoses
      • Hose Clamps
      • Radiator Hoses
      • Radiator Support
      • Radiator Part #'s
      • Shroud Part #'s
      • Thermostats
      • Water Pump #'s & Illustrations
    • Driveline >
      • 4WD Front Hubs & Rotors
      • Axles & Differentials
      • Bell Housings
      • Brakes
      • Calculators
      • Clutches and Linkage
      • Drive Shafts
      • Engine Plates
      • Rear Axle Vents
      • Skid Plates
      • Transfer Cases
      • Transmissions >
        • Transmission & Transfer Case Ratios
        • Automatic Transmission >
          • Automatic Transmission Applications
          • General Automatic Transmission Service
          • Automatic Overdrive (AOD)
          • C6
          • Kickdown Linkage
          • Neutral Start Switch
        • Manual Transmissions >
          • Manual Transmission Applications
          • General Manual Transmission Service
          • 3.03 3-Speed Toploader
          • NP435
          • Single Rail Over Drive (SROD)
          • TOD & SROD Transmissions
          • TOD
          • Warner T-18 & T-19
          • ZF5
        • Over/Under Drives
      • Speedometer Gears, Cables, & Sensors
      • Wheels & Tires
      • Wheel Covers
    • Electrical >
      • 3G Conversion >
        • 3G Conversion - In Development
        • 3G Writeup From Lucas
      • Alternators
      • Ammeter
      • Batteries
      • Battery Cables
      • Battery Trays
      • Circuit Protection
      • Clocks
      • Computer Internals
      • Connectors
      • Distributors
      • Electrical Connectors
      • Electronic Engine Control (EEC)
      • Electricity 099
      • EVTM >
        • 1980 EVTM
        • 1981 EVTM
        • 1985 EVTM
        • 1986 EVTM
        • 1996 EVTM >
          • Index
          • Charging System
          • Daytime Running Lamps
          • Engine Control - 4.9L
          • Engine Control - 5.0L
          • Engine Control - 5.8L Under 8500 GVW
          • Engine Control - 5.8L Over 8500 & 7.5L EEC-IV
          • Engine Control - 7.5L EEC-V
          • Engine Control - Turbo Diesel
          • Fuse Panel & Circuit Protection
          • Grounds
          • How To Use This Manual
          • Ignition System
          • Keyless Entry
          • Power Distribution
          • Speed Control
          • Starting System
          • Transmission Control - 4R70W
          • Transmission Control - E4OD
      • Gauges
      • Ground Wires >
        • Engine-to-Firewall Ground
        • Battery to Ground
        • Battery to RH Fender
        • Firewall to Hood
      • ICVR
      • Ignition
      • Lighting >
        • Dome and Cargo Lights
        • Fog or Driving Lights
        • Headlight Wiring Harness
        • Lighting & Calculations
        • Tag Lights
      • PMGR Starter Wiring
      • Radios
      • Relays
      • Sending Units
      • Speed Control
      • Standard Wire And Color Codes
      • Switches
      • Tachometers
      • Terminals & Connectors
      • Voltage Drop Testing
      • Windshield Wipers
      • Wiring Connectors
      • Wiring Diagrams
      • Wiring Harnesses
      • Wire Routing
    • Emissions >
      • Understanding Emissions Controls
      • Inferred Mileage
      • Thermactor Systems
    • Engines >
      • Compression Ratio Calculator
      • General Engine Service
      • 3.8L (232) V6
      • 300 Six
      • Windsor Series
      • 351M and 400
      • 385 Series
      • IDI Diesel
      • Drive Belts
      • EGR Valves >
        • EGR System Description & Testing
        • EGR Spacer
        • Gasket: Carb/EGR to Intake (9447)
      • Flywheels
      • Manifolds, EGR, Heat Valves, etc
      • Engine Swaps >
        • 300 Six to Small-Block V8
      • Pulleys
      • Starters
    • Exhaust Systems
    • Exterior >
      • Beds, Tailgates, and Components
      • Bumpers
      • Exterior Mirrors
      • Exterior Moulding Retainers
      • Exterior Trim and Moulding
      • Frames >
        • Engine Perches
      • Fuel Filler Doors
      • Name Plates
      • Push Bars
      • Spare Tire Carriers
      • Stationary Glass - Butyl Type Seal
      • Tape And Decal Application
    • Fasteners & Illustrations >
      • Fastener Pictures
      • Fenders and Aprons
      • Frame
      • Headlights and Turn Signals
      • Hood
      • Radiator and Grille
    • Fuel & Air Systems >
      • 1985-1986 Fuel System Adjustments
      • 460 Fuel Systems
      • Air Cleaners
      • Carburetors, Chokes, & EFI >
        • EFI Idle Speed Adjustment
        • Jetting
        • How To Find Carb Parts
        • Chokes
        • Carter YFA 1bbl
        • EFI
        • Edelbrock
        • Motorcraft 2150
        • Holley 4180C
        • Motorcraft 7200 VV
      • Correct Cold Starting Procedures
      • Diagnostics
      • Fuel System Illustrations >
        • Fuel Filler Pipes
        • 1980-84 F-Series & Bronco
        • 1983-84 F-Series Diesel
        • 1983-87 F350 Chassis Cab DRW
        • 1985 F-Series 302 w/EFI
        • 1985-87 Bronco
        • 1985 on F-Series
      • Fuel System Part #'s >
        • Fuel Filler Pipes
        • Fuel Senders & Pumps
        • Fuel Tanks
        • Fuel Tank Selector Switch
        • Fuel Tank Selector Valve
        • Fuel Tank Shields
        • Fuel Vapor Valve
        • Fuel Vapor Separator
      • Fuel System Wiring
    • HVAC >
      • Blend Door Repair
      • HVAC Systems
      • 300 Six Compressor Illustrations
      • Factory A/C Brackets
    • Interchange >
      • Air Conditioning Interchange
      • Alternator Interchange
      • Brake Interchange
      • Carburetor Interchange
      • Crankshaft Interchange
      • Diesel Injector Pump Interchange
      • Distributor Interchange
      • Fuel Pump Interchange
      • Head Interchange
      • Starter Interchange
      • Steering Interchange
      • Window Lift Motor Interchange
      • Water Pump Interchange
    • Interior >
      • Behind The Seat Storage
      • Boots
      • Carpet
      • Dash
      • Doors >
        • Door Locks
        • Door Panels
        • Electric Windows & Locks
        • Handles & Boot
        • Vent Windows
        • Windows
      • Horn Pads
      • Insulation
      • Interior Soft Trim
      • Interior Trim
      • Instrument Panel Name Plates
      • Instrument & Radio Bezels
      • Kick Panels
      • Knobs
      • Painting Gauge Needles
      • Rear Corner Trim
      • Rear View Mirror
      • Salvaging Rosewood
      • Seat Belts
      • Seat Interchangeability
      • Seats & Seat Tracks
      • Sill Plates
      • Steering Columns & Steering Wheels
      • Sun Visors
    • Picture Galleries >
      • 1981 F100 With 318 Miles
      • 1983 XLS Survivor
      • 1983 Ford Bronco 4x4 Dobbs-Stroppe Team Chase Car
      • 1983 Bronco Survivor
      • 1984 Bronco XLT
      • 1984 F150 XL
      • 1984 F150 Survivor
      • 1984 FORD F-150 XLT PICKUP
      • 1985 F-150 Survivor
      • 1985 F150 4×4 Flareside
      • Big Blackie
      • Big Blue >
        • Big Blues Documentation
      • Dad's Truck >
        • Air Cleaner
        • Aluminum Wheel Refinishing
        • Electrical Components >
          • Alternator
          • Battery
          • Power Distribution
        • Gauges
        • Engine
        • Frame
        • Seats
        • Transfer Case
        • Transmission
      • Rusty
    • Reference >
      • Hose & Fittings
      • Standard & Utility Parts Catalog
    • Specifications >
      • Assembly Plants
      • Axle Ratios
      • Body Codes - Interior
      • Build Sheet Interpretation
      • Dimensions and Weights
      • Interior Paint
      • Calibration Codes
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saginaw conversions

How to convert your Bullnose truck to use the Saginaw power steering pump.

Ford's C2 power steering pump was used on both the F-Series and Bronco Bullnosed trucks.  But, it is noisy and lacks the boost of the Saginaw pumps used in the E-Series vans, so many people convert their Bullnose to use the Saginaw.  In some cases that is easy, and some not.
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How to install a Saginaw Power Steering Pump in a IDI V-Belt Truck
By Andrew Ebers (IDIBronco)
This will be an overview of how I was able to install a Saginaw power steering pump from a Ford van into my IDI powered Bronco.  For a little background, I had noticed the steering assist from my stock C2 pump had been getting less and the noise had been increasing.  I decided to do something about the problem and started to do a little research and found that the parts in the van I had sitting out back could be used (with some work) to convert to the Saginaw pump and correct the problem.  I try to use what I have access to rather than go and buy new parts or conversion pieces, so in typical fashion I dug around my junk parts and found most of what I needed to complete this project. 
STARTING POINT        
COMPLETED SWAP​
Details:
1985 Ford Bronco 
1985 F250 Powertrain (6.9 IDI) 
1980 Ford E150 parts van (300 I6) 

Required Tools:
Mig Welder 
typical Hand tools (wrenches, screw driver, etc.) grinder, saw, file ​
Required parts:
Saginaw Pump 
Stock Saginaw Pulley 
Stock Saginaw Mounting Bracket (modified) 
V Belt 1 inch shorter than stock (gates 9590, 59.5" length) 
Round Tube 1" O.D. & 1/2 I.D., 6" long minimum (or close dimensions) 
Power Steering Hose (I ordered a new one for a 1986 van, gates 359470) (modified) ​
Directions

Remove parts required from the parts donor.  This included removing the Saginaw pump, complete with bracket and pulley.  This turns out to be quite easy if you have a van with a 300 I6, No Ac, and flat front tires.  The access to the parts is pretty simple. 

​I went ahead and removed the pressure and return hoses at this time with the pump, but as it turned out I didn't use either of them. 

​Next, I pulled the C2 pump, pulley, mounting bracket out of the bronco as a unit and also removed the power steering pressure hose as it would not be reused. 
Picture
MEASURING THE C2 OFFSET

Now the fun part of measuring everything begins.  I did this conversion with the plan being to match the offset of the center line of the pulley from the mounting surface at the front edge of the C2 bracket.  You will have to be a bit understanding, because finding pictures that will demonstrate exactly what I am talking about are not the simplest to come up with...   


I quickly made the executive decision to let the measurements be "Close Enough" on all areas of this project as making a part like this accurate to more than about 1/16 of an inch is a bit ridiculous.  V belts can handle a bit of misalignment and I feel this is well within the limits of their use.   I measured this offset as being 1 3/8".  ​
Picture
MEASURING THE SAGINAW OFFSET

When I measure the offset of the Saginaw pump and bracket I measured the offset to be 1 3/4".  This means If I ran the Saginaw pump and bracket against the mount it would offset the pump 3/8" too far forward (1 3/4" - 1 3/8" = 3/8').  To rectify this I would have to space the pump and bracket 3/8" farther to the rear of the engine compared to how it was originally intended.  Additionally, the bracket is very different in design compared to the C2 bracket.  The C2 bracket I measured to be 4 9/16" from front to back where it mounts between the front mount and the head.  This is important because it is how the pump is held rigidly in place both front to back and provides the twisting support to offset the torque applied from the belt.  The issue is the Saginaw bracket from the 300 I6 is only approximately 1/4" thick.  So in order to make the full 4 9/16" required I would have to have a spacer behind the pump bracket as well.  The spacer would need to be sized at 3 15/16" (4 9/16" - 3/8" (front spacer) - 1/4" (bracket thickness) = 3 15/16"). 
​
Picture
​PIVOT-TO-ADJUSTER-BOLT DISTANCE

The next issue is the pivot to adjuster bolt distance.  
The C2 bracket has a spacing of 3 1/4".
The Saginaw bracket has a spacing of 3". So you have to modify the Saginaw bracket to get the center of hole to center of hole distance to be 3 1/4". ​​
I first attempted to just move the pivot hole to make this distance work within the confines of the bracket area.   I drilled a hole where I thought this would work, but it created 2 problems.  You cannot move the pivot hole that direction because it reduces the amount of area the pump and bracket can swivel to adjust for belt tension, and the bolt will no longer clear the pulley for installation. 
​​
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I then decided to fully modify the bracket.  Up until this point I had thought I could just get away with drilling a hole and some spacers, with no welding.  The welding would now be required in order to get 3 1/4" spacing between the holes and keep the ability to adjust the belt/install the bolt.

What I decided to do was to cut some of the bracket away to weld a 4 9/16" tube to the bracket to make the bracket mimic the design of the C2 bracket. The red circle indicates where I will cut it away in the picture on the left.  In the picture in the center you can see I had outlined in blue where I intended to remove the metal for the tube to be mounted.  You have to grind away the welded nut on the back of the bracket for the hole you intend to modify.  And the picture on the right shows the added spacer.​​
TUBE MEASUREMENTS

Then I took several pictures to show the critical measurements. ​
TEST FITTING & GUSSET INSTALLATION
Next, I test fit the pump in the Bronco to check for clearance, alignment, and belt length.  It was apparent the factory belt would be too long, and I had plenty of room for gussets.  So out it came again for gussets. ​
I then cleaned everything and shot it with some primer.  Here I am including several pictures from many angles, as the primer makes everything easy to see.  If someone wants to duplicate my work these may be helpful. ​
I then shot it with a coat of black paint.​
Picture
The only real pictures I have of the pump installed aren't great, but the results of the conversion are wonderful.  There no longer is squealing and I have great assist for the steering even when stopped. ​
Conclusions

I would highly recommend anyone to do this conversion.  The C2 pump has been a great annoyance for me on several vehicles now.  I have converted a couple of them previous to this adventure, but this swap was by far the most involved.  I want to thank anyone who has helped or posted about doing this conversion as I did read and research a great deal before embarking on the project.  I did try to include some of the problem solving required to get the alignment of the belts to come out, as this same process can work for different pulley offsets and brackets if you cannot access the same bracket I used.  You just have to verify where you want the pulley to end up and space everything accordingly.  I could have used a gas V8 bracket to modify, but I felt that the 300 I6 bracket offered a greater amount of simplicity as it is just a simple flat bracket and not a horseshoe shape.  In the end I think I ended up with a pretty strong bracket and a great pump.  Now I need to decide what the next project will be.


​
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