Mud in my Veins
Join Date: Dec 2000
Location: Memphis, TN
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Re: \'84 to \'94 exchange....
You can't put a 92-97 dash or instrument cluster in an 80-91 body, but I put a 92-97 speedometer (PSOM) and 87-91 fuel and volt meters in my 80-86 cluster. The meters were the only things necessary to put a COMPLETE 95 engine (not just EFI parts) into my truck - I did the speedo for other reasons... As to the speedo cable, 92-97 trucks don't have one: the PSOM (Programmable Speedometer/Odometer Module) is electronic; it has only one moving part: the needle. (That's why I wanted it - my speedo and cable and drive gears were shot and they weren't calibrated to my tire size anyway.) So if you put a 9" in a 92-97, you will have NO SPEEDOMETER. If you put one in an 87-97, you will have NO ABS (Anti-lock Brake System), and no 4-Wheel ABS on 93-96 Broncos. You have to have the 87-97 VSS (Vehicle Speed Sensor) in the rear end to run those systems... and the cruise, and the E4OD, and the engine computer (EEC-IV PCM) reads it for some reason, too. (The 87-92 t-case VSS only operates the cruise.) The aftermarket ignition system will not help the fact that the 92-97 ignition switch is electrically different from the 80-91 and so the 92-97 won't work with an 80-91 engine wiring harness - you'd have to design some custom circuits. (Going the other way is much easier - I've done it.) The alternator is the least of the problems.
I spent a total of $1300 for a late, low-mileage 4.9L (the V8's were only $200 more) and spent less than a week installing it. You could get a complete front clip (with core support) for about as much and have it painted for a few hundred. Total: about $3K and 3 weeks. A good used Bronco, even one with a blow engine, will be double or triple that (including the time to track one down, inspect it, and make a deal).
I had an AutoZone u-joint shatter while I was driving normally on-road, and a tie rod end just drop loose, also while driving normally on-road. Neither was more than a few months old and, fortunately, both were at low speeds. After that, I removed EVERY AZ part from my truck and made them give me FULL refunds on everything (including things like wheel seals) and they paid me $200 not to sue them for nearly killing me twice.
83 Custom w/95 4.9L EFI, 78 NP435, 83 NP208, 83 D44IFS 3.07, 87 Ford 8.8ABS 3.08, Michelin LTX AT 31x10.50R15