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Old 11-07-2016, 06:32 PM   #1
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92 YJ Gets a Ford 5.0

My AX-15 died, with the help of some water intrusion, and I need to fix it. Problem is, people want way too much for that transmission and I always wanted to do the SBF conversion, so might as well do it now.

I picked up a 96 Ford Bronco for $500. Drove it 3 hours running 70-75 mph with no issues. Not a bad deal for $500.

I have already pulled the T-case and transmission from the donor. M5OD R2 (the Mazda 5-speed) paired to a BW 1356. The engine will probably get pulled this week, a 5.0. I also has a limited slip diff in the rear, so that will get pulled, inspected, rebuilt, and installed in the jeep's rear axle. Better than an open diff, for now.

So far I have found a few things that made the Bronco less than ideal, but nothing that makes me want to throw a wrench at it. The trans needs a new 1-2 shift fork and the input shaft has some wobble to it. Makes some bearing noise too. So it's getting a rebuild (might as well before I get everything in there).

The T-case is solid, no issues. The engine looks like it has been out before, but she ran very smooth. A bit light on power, but that's no issue for me. The emission components were hacked off, but that will get cleaned up. (no smog check where I live)

The immediate goal is to get everything in and operational quickly. It's dune season and I don't have a jeep running now, so I need to make it a quick turnaround so I can get out there before it gets hot. Summer it will get the engine redone so I can get some decent power to the tires and who knows what will be next. This Jeep will be a forever project

Advice and pointers are most welcome!!
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Old 11-07-2016, 09:20 PM   #2
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I'll be keeping my eye on this for sure! A Bronco will probably be my next vehicle, that or a full size Blazer.

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1990 Yamaha TW200.

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Old 11-07-2016, 10:23 PM   #3
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My buddy has a full size bronco. I like them as well but I prefer smaller vehicles, they just get around better.

This is the YJ that will be getting the 5.0, M5OD R2, BW 1356, and limited slip from the donor bronco
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Old 11-08-2016, 09:11 AM   #4
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I drove '96 bronco for 7 years before I wrecked it. I may be misremembering, but I thought that the 5.0 and 5 speed were discontinued in 1995 and only the 351/auto was available in 1996 because they were killing the bronco to introduce the expedition. Great drivetrain though!
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Old 11-08-2016, 09:24 AM   #5
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I cannot say for sure that this drivetrain is OE, but the 96 models came with either the 5.0 or the 5.8 and M5OD R2 was the only manual option. There were two auto options. So far as I can tell it seems to be the OE drivetrain, but I'll have to look at the VIN to be sure. 96 was the last year though and it was killed to make way for the expedition, unfortunately
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Old 11-10-2016, 08:29 AM   #6
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Got the 5.0 out, time to clean it up a bit and then to pull the drivetrain from the jeep
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Old 11-11-2016, 08:09 AM   #7
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Originally Posted by Matt_C View Post
I cannot say for sure that this drivetrain is OE, but the 96 models came with either the 5.0 or the 5.8 and M5OD R2 was the only manual option. There were two auto options. So far as I can tell it seems to be the OE drivetrain, but I'll have to look at the VIN to be sure. 96 was the last year though and it was killed to make way for the expedition, unfortunately
I bought the last new bronco off the lot from my local dealership and drove it for 6 years before wrecking it. I loved that truck. Good luck with the swap!
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Old 11-19-2016, 11:10 PM   #8
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Finally got the Jeep's transmission and t-case out. The shifter seal was toast, so now I know where I was getting water into it... Oh well. So, anyone need a t-case or 4.0?

On another note, I noticed a while back that my winch was loose. I finally puled it and found out why. There was only one bolt left that was actually holding. I'm going to need to cut out the broken areas and weld in some new steel. I plan on making a new bumper and winch plate that will incorporate some towing eyes for a tow bar and shackles for recovery. Ideas?
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Old 11-20-2016, 08:22 PM   #9
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Build thread for OJ, my YJ. 1993 Wrangler S 2.5L/AX-5/NP231, Spartan Locked Dana 30/open Dana 35 @ 4.10, 2.5" OME HD springs and Rancho RS5000 shocks, Barricade 9500 winch, custom front and rear bumpers, 136 amp alternator, 30" General Grabber AT2 tires.
1990 Yamaha TW200.

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Old 11-21-2016, 08:22 AM   #10
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That looks very tough and rugged, I like it. How did you mount it to the frame? Did you weld it to the frame or is it bolted in?
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Old 11-21-2016, 11:35 AM   #11
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That looks very tough and rugged, I like it. How did you mount it to the frame? Did you weld it to the frame or is it bolted in?
I actually had some pretty significant frame repair to do. It looked like there was metal there, but I wanted to make sure it was strong. It turned out to be paper thin, so I repaired it. I don't have the skills to make it like the original frame was, in order to bolt it on, so I welded the bumper on.

So far I've winched myself up rocks twice, and winched a Cadillac Escalade up a steep hill.. No bends.

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Old 11-21-2016, 09:56 PM   #12
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Thanks Mudmagnet, you have given me some ideas

I finally got the 4.0 out and the 5.0 and M5OD in place. The clearances look better than I could have hoped, so

I think I will bring it forward about 2 inches and center is a bit more. My limit for that will mostly be the power steering pump touching the steering shaft. Might have to bring it up an inch too. I would like to have it as low and far back as possible, but that might make for too short of a driveshaft. Ideally I would go ahead and push the rear axle out, but that would extend the project time. I'm thinking I will make the new engine x-member with provisions for relocating the engine later down the road if I find that I'm not happy with it. Another thing is the oil filter will probably need to be relocated, which really won't be an issue.
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Old 12-12-2016, 05:09 PM   #13
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Wow, I guess it has been nearly a month since I updated this. I'll have to add some new picks when I get the chance.

I have the engine, trans, and TC installed. I fabbed up a cross member for the 5.0 and made it adaptable to the factory ford mounts. Welded it to the Jeep's frame once I checked all of my clearances. The factory Jeep skid plate/trans cross member bolted up, mostly. Just had to add a slot to where the original trans mount went in. The ford mount has a wider bolt pattern and larger studs. Still has the 2" lowering spacers between the frame and skid plate, but those will get eliminated once the body lift gets put in. I think. I'm mostly happy with it, but the new length plus the size of the TC makes a 2" body lift required. Not a fan of body lifts, but cutting out the jeep tub is not something I want to do. I will have to extend the rear axle out a bit. I'm thinking of getting some 84-88 Toyota pick-up or 4 runner leafs. They have a center pin that would push the axle back 5" but their overall length is only about 2" longer. We'll see if it works. Then I'll have to figure out what to do with the gas tank.

On another note, the VSS might be a little more trouble than I had hoped. The Ford uses a reed switch and the Jeep uses a hall effect pickup. That means I have a square wave VSS and a sine wave speedo. Not sure how I will address that... yet. Bonus though, the 8.8 that was already in my jeep has the VSS in place. Ford used the rear diff VSS, none in the TC, for the 96 Bronco's speedo and ecu speed.
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Old 01-02-2017, 08:38 PM   #14
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Wires EveryWhere!!

My progress has not been as forthcoming as I had hoped, but it is getting there. I got the wire harness done, what a relief. That was one hell of a thing to do. I ended up putting in the 2" body lift and got rid of the spacers that lowered the skid plate, looks so much better. T-case clears the tub by about .12". I still have a large punch list of things to do before I take it to my friend's shop for drive shafts and exhaust, but hopefully I'll get that done this weekend. I still need to sort out the speedo and tach. Not sure if the Ford components will work with the Jeep gauges. I know the oil sending unit won't, the Ford one is an on/off switch that activates at 6-8 psi. Lame. But easy fix. Now for a few progress pics
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Old 01-02-2017, 11:12 PM   #15
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Looking good so far! The M5OD just seems like too long of a transmission to me for a wrangler. I'm curious to know if the driveline angles cause vibrations or not.
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Old 01-03-2017, 12:25 PM   #16
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Looking good so far! The M5OD just seems like too long of a transmission to me for a wrangler. I'm curious to know if the driveline angles cause vibrations or not.

It will be a challenge, the M5OD is 4.5" longer, but the engine is also 2" shorter (from drivebelt to bell housing). But then I went and shoved the engine pretty far back and down. I'm going to have a very short shaft, but I will move the rear axle eventually anyways. I just might have to do it sooner than I had planned too. As is I need to clock the rear axle so it points to the rear flange of the TC so I can use the Double Cardan. The front drive shaft will contact the skid plate with TC being so far back and clocked down, so I need to mod that too. The front driveshaft will be ridiculously long.
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Old 01-03-2017, 01:15 PM   #17
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It will be a challenge, the M5OD is 4.5" longer, but the engine is also 2" shorter (from drivebelt to bell housing). But then I went and shoved the engine pretty far back and down. I'm going to have a very short shaft, but I will move the rear axle eventually anyways. I just might have to do it sooner than I had planned too. As is I need to clock the rear axle so it points to the rear flange of the TC so I can use the Double Cardan. The front drive shaft will contact the skid plate with TC being so far back and clocked down, so I need to mod that too. The front driveshaft will be ridiculously long.
I'm planning on a DIY skid plate for mine. On my 350 swap with the 700r4, my rear shaft is going to be a whopping 2" longer than it was with my ax15 if I am going to use my np231 with the sye it has. This is because the 350 sits further forward than my 4.2l did. I'm thinking of getting a super short np241 sye from JB conversions so I can have an even longer shaft with stronger t-case. I have a dodge np241 that has the same input splines and bolt pattern as my jeep np231.
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Old 01-03-2017, 02:16 PM   #18
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I'm planning on a DIY skid plate for mine. On my 350 swap with the 700r4, my rear shaft is going to be a whopping 2" longer than it was with my ax15 if I am going to use my np231 with the sye it has. This is because the 350 sits further forward than my 4.2l did. I'm thinking of getting a super short np241 sye from JB conversions so I can have an even longer shaft with stronger t-case. I have a dodge np241 that has the same input splines and bolt pattern as my jeep np231.
Lucky for me, the 1356 TC has a flange and so does my 8.8. It would be impossible with a SYE. Or at least it would be impossible without moving the rear axle back a foot or so...

The skid plate/trans x-member worked for me. The holes nearly lined right up. I just had to enlarge one of the slots and make a new one since the Ford trans mount had a wider pattern. I could not be more pleased with how well the engine and trans fit.
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Old 01-11-2017, 12:50 PM   #19
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Finally got the wire harness done and fired up the 5.0. Definitely needs a muffler, all my neighbors know that I have it running too... Hopefully I will get it to the shop for drivelines and exhaust this weekend, but life might have other plans for my money. We shall see. I need a new radiator too...
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Old 01-11-2017, 01:52 PM   #20
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Finally got the wire harness done and fired up the 5.0. Definitely needs a muffler, all my neighbors know that I have it running too... Hopefully I will get it to the shop for drivelines and exhaust this weekend, but life might have other plans for my money. We shall see. I need a new radiator too...
Picture's and video! I need some motivation to finish my swap haha
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Old 01-12-2017, 07:12 AM   #21
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Picture's and video! I need some motivation to finish my swap haha
I've been procrastinating on uploading pics lol. Actually, I talked with a friend last night about towing my Jeep over to his shop this Friday. Going to get started on the exhaust and find out what my options are going to be for drivelines. He seems pretty confident that we can make it happen, just need extreme angle U-joints and maybe some custom yokes. He is swamped with driveshafts right now though, so I'm hoping I can trade some labor for shop time. It would be win-win.
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Old 01-14-2017, 06:16 AM   #22
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Jeep got towed to the shop, should be doing the exhaust today. Keeping it simple and cheap, nothing fancy. If time permits, I might get the specs I need to put a parts list together for the driveline today too. The front shaft should be easy. Need new perches for the 8.8 since I need to clock it no matter which approach I take, so probably not doing that today. Only one guy in town carries those and I think he is closed on Saturdays.

Oh yeah, I had an extra fan from one of my Ford ZX2s that I tried to put on my old Jeep radiator to see if it would fit. It's like it was made for it, nearly bolted on. Hopefully it will flow enough CFM. It's a dual speed fan so it should, but the real test will be when it warms up later this year. I need to get some thermostatic switches to control the speeds, but I'll just put it on a toggle switch for now. New radiator, 3 core aluminum, is inbound. Need the extra cooling capacity for that V8. Plus the Jeep radiator is shot, as you can see in the photo. So much rust, drives me insane to see people use straight water in their cooling systems... The PO of the ZX2 and the Jeep were those people.
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Old 01-15-2017, 02:43 PM   #23
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Got the exhaust done. My friend let me use his lift and gave me pointers on how to make the bends and use the bending machine. It was fun to learn how to do that and I ended up doing a fairly good job at it. The pipe comes out at the original location but I made it a bit shorter than OEM. Ended up using 2" from the manifolds to the Y then joined them into a collector that I made using 2 1/2" pipe that joins to the 2 1/4" pipe that goes to the 40 series flowmaster muffler. Did 2 into 1 to keep it simple and that 5.0 isn't hopped up yet, so no need for anything more. Yet. Hopefully I'll start on the driveshafts tomorrow.
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Old 01-24-2017, 09:29 AM   #24
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Well the driveshafts are being a bit difficult. The rear is 10 5/8" long... The slip yoke is longer than that!! But I'll be able to use a modified one for now. Relocating the rear axle is definitely a must in the long run, but for now I just want to get it driveable so I can beat on it a bit and see if there is anything else that needs reworking. The front shaft is 47 1/2" long, so it's going to be fairly easy. Just waiting on the new tube to show up for that.
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Old 01-30-2017, 01:04 PM   #25
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Drove the Jeep Saturday. It's nice having the V8 power. Still a number of little things to button up. The super short rear driveshaft is holding up pretty well, no crazy vibrations or anything. Still plan on pushing the rear axle back later down the road though.

Went to drive it yesterday and a freeze plug failed, spectacularly... The PO of the Bronco did not maintain the vehicle at all, let alone well. I really should have put in new freeze plugs before I did the swap... Doh.. And the power steering pump died. Not a surprise, Ford never did make a good one. I was told that the E series vans that came with a Windsor V8 had Saginaw pumps, so I may look into getting the brackets for that and get completely away from the Ford pump.
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LSD 8.8, custom dash, front and rear bumpers, extended rear axle, fender mods, etc, etc, etc
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Old 02-06-2017, 04:13 PM   #26
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It's Alive!!! Muhahahaha!!!

Took the Jeep out this past Saturday for her maiden off-road trip. It did quite well, not driveshaft issues. Much more power, and I absolutely love the V8/Flowmaster sound. Still have some things to work on. It has a power steering leak from the pressure line at the pump (I put a new pump in). The radiator hoses leak, but no surprise there. They are temporary and I'm waiting on universal hoses to come in. Temp gauge still is non-op. It's a wiring issue that I need to chase down. Still have no speedo, but that hardly hurts my feelings. Still need to get that sorted out though.

I'm hoping to get my new 20 amp outlet installed in my garage this week. My welder keeps tripping the breaker on the one outlet that I have in the garage, and it's a 20 amp outlet. This dedicated outlet will allow me to run a 10 ga cord so I can get the welder out into the driveway. Once that is done, I'll be able to start on the custom bumpers. Because I need my winch. To recover other vehicles, of course. lol
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LSD 8.8, custom dash, front and rear bumpers, extended rear axle, fender mods, etc, etc, etc
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Old 02-14-2017, 01:39 PM   #27
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Setback...

So the water pump started leaking. Like the Titanic after hitting an iceberg. I took it off and found a broken stud (yay...). It turned out that the previous owner of the 5.0 broke it, stuck it back in with 5 gallons of RTV, and pretended that it was good. Bastard. I pulled the engine and got it on the stand. Pulled the oil pan and front cover and found that the PO had attempted to extract the broken stud. In the worst way imaginable. There was a drill bit or easy-out broken off in the hole and they had drilled holes around it. So bottom line is the block is toast (unless I want to pay for lots of machinist hours, which I don't).

I am going to go and look at a 97 Explorer today. It has a 5.0 with GT40 or GT40p heads, which would be nice to have. Plus a few other goodies. We shall see. Clock is ticking though, Baja 250 is in a month and a half and I want the jeep ready for that trip.
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1992 YJ with 5.0 Ford, M5OD R2 Trans, BW 1356 TC, Ford 8.8 rear axle, sitting on 33 x 12.50 BFG MTs.
Aluminum 3-core rad, Electric fan, 8k winch
-More mods to come-
LSD 8.8, custom dash, front and rear bumpers, extended rear axle, fender mods, etc, etc, etc
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Old 02-14-2017, 02:48 PM   #28
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Damn, that's why I'm going through a complete rebuild of everything I'm putting in. The 350 block I have actually has a crack in it so now I'm looking for a 4 bolt main with 1 piece rear main myself. These v8 swaps seem to be more trouble than they're worth sometimes. I've missed out on months of wheeling already.
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Build Thread 1989 YJ, (Soon to come: TBI 350, 4l60) np231 sye/wide chain/6 pinion planetary, D30 ARB & Ford 8.8 ARB 4.56, 31" rollers for now, bds 3.5" springs, 1" Boom Shackles.
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Old 02-15-2017, 05:54 AM   #29
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Damn, that's why I'm going through a complete rebuild of everything I'm putting in. The 350 block I have actually has a crack in it so now I'm looking for a 4 bolt main with 1 piece rear main myself. These v8 swaps seem to be more trouble than they're worth sometimes. I've missed out on months of wheeling already.
I hear ya, I've missed another dune season... But, I went and looked at that exploder yesterday and, well, I need more driveway space lol. The guy talked himself down to $200. It turned out to be a 96, which is even better for me. It runs, drives, but the body and interior are a bit crappy. The really nice thing is now I have another Ford 8.8 with discs that I can sell to get back some of my money. The engine has GT40 heads too, that will make my life a bit easier. And EDIS, I'll be saving that for later. Don't want to miss the Baja 250 to rewire everything. I'll have to post more pics later.

Oh, V8 swap is still worth it I think. More power with an engine that has way better aftermarket support is hard to beat. Even if the project has a few setbacks and takes longer than hoped.
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1992 YJ with 5.0 Ford, M5OD R2 Trans, BW 1356 TC, Ford 8.8 rear axle, sitting on 33 x 12.50 BFG MTs.
Aluminum 3-core rad, Electric fan, 8k winch
-More mods to come-
LSD 8.8, custom dash, front and rear bumpers, extended rear axle, fender mods, etc, etc, etc
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Old 02-15-2017, 09:27 AM   #30
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Oh, V8 swap is still worth it I think. More power with an engine that has way better aftermarket support is hard to beat. Even if the project has a few setbacks and takes longer than hoped.
I know the end result will be well worth it, it's just getting there that's difficult

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Build Thread 1989 YJ, (Soon to come: TBI 350, 4l60) np231 sye/wide chain/6 pinion planetary, D30 ARB & Ford 8.8 ARB 4.56, 31" rollers for now, bds 3.5" springs, 1" Boom Shackles.
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