Bronco Restoration: Day 2 - Building the Axles

I bought this Bronco for $2,000 and my plan is to fully restore it, and at the end sell it. I’m keeping track of every dollar and hour spent so see what kind of profit I could get in the end.

If you are doing a Bronco Restoration or think you will want to in the future, subscribe to my email list.

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In the last episode, I sent the frame off to get powder coated from a shop in Georgia. Its back now and looks great. The powder coast cost me $450, plus a couple hours getting it to and from the powder coater. Now it’s time to start building this Bronco on top of it.

In this episode, I tear down my Dana 44 front axle and my Ford 9 inch rear axle. Then, I send them off to be powder coated to match the frame. Battle Born Coatings in Clarksville, TN did the coating and did a fantastic job.

Then, I sent the axles to Tennessee Classic Trucks to build the axles. Carl is a Yukon Gear and Axle Master Installer, and Mike is just a gear and axle wizard. They did a great job and really know their stuff.

00:00 - How to remove Early Bronco suspension
00:38 - Bronco Restoration Recap
02:13 - What suspension parts to keep in Bronco Restoration
02:58 - Ford 9 inch tear down
03:47 - What tools are needed for Bronco axle tear down
07:28 - How to remove knuckles from Dana 44
09:28 - Powder Coat the Axles
10:14 - Parts to re-gear Dana 44 and Ford 9 inch
10:35 - How to re-gear a Dana 44 front axle
11:15 - How to re-gear a Ford 9 inch

There are a few tools that I used to take everything a part. If you are doing this, I would recommend getting these tools.

I bought most of the parts to re-gear the axles from Toms Offroad. I’ve been shopping at Toms for a long time, and they have a great selection of parts and great prices.

Dana 44 parts
**I re-used my Dana 44 carrier**

Ford 9 inch parts:

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#earlybronco #classicbronco #fordbronco

[rascalpanda]

Great video. I love this format with the cost and Time spent. This will help a lot of people to understand just what it takes to building something like this. Can't wait to see the finished Bronco.

[alfonsopastrana]

That’s what o call extreme measures hahaha love it keep with the serie love it!!

[aaronkelly]

Thanks for sharing the process! Just finished a frame off on my 66 and getting ready to drive from Washington state to Florida!

[davestewart]

Thanks for the video, this is great watching your progress 👍😁

[rafaelbrango]

Awesome idea with the videos. I'm trying to restore a 1993 Bronco. This will help me a lot.
Thanks!

[nickanderson]

Awesome series! Thank you for posting and looking forward to the next episode.

[ShawnsEarlyBroncos]

I love this. It is really cool how you are doing this process. Making videos and editing is time consuming and I know this all too well. I really appreciate your videos. You always inspire me. Keep it up!!!

[mikestoneclark]

Great content! So well presented and your sense of humor actually had me literally laugh out loud a number times (I too break stuff and learn the hard way all the time). I'm enjoying them to the point that I'm watching videos that don't even apply to our bronco (a 74 coyote built approx 5 years ago). Its sweet and badass at the same time, but there are a few things that need revisiting. I'm going through them one at a time, not rushing, and replacing anything that needs attention with the best of the best. I really appreciate the details and insight you provide along with cost and 'regular joe' man hour summaries. I just subscribed and looking forward to watching your build. BTW, coyotes are incredible but they are huge. The clearances are so tight and the space to work is so limited, I think it was super smart to stay with the traditional 302 for your build. Lastly, regarding transmissions - we have the 4r70w as well. I like it but wouldn't mind the 6 speed. 4r70 is basically old school 3 speed with OD. I think it makes it 'feel' older. I don't know the ratios, but guessing the 6 speed would feel much more modern and have a lot less rpm drop between gears. Anyway, Keep up the great work!!

[nickefgen]

Great video happy to see the progress on the bronco

[billh]

FWIW-If you have the room for it, the harbor freight press is good for the money. I’m always finding reasons to use it now that I have it.

[superdutywd]

Great video. Who did you find to powdercoat the frame. I am in north Georgia and have a 73 and 74 frame that needs coated.

[markhavelka]

Great video format. I like the way you’re tracking expenses and time. Did you include any traction devices while re-gearing?
I recently re-geared to 4.56, myself. Have been happy with these gears, 33” tires and 4R70W/Explorer 5.0.

[NashvilleEarlyBronco]

Oh man, I just saw a typo in the video on my prices. Anyone else catch that? My final price should be up $50

[AsgeirSaem]

Great and Interesting video. Out of curiosity, what spline count did you choose for the 9" and what locker and carrier?

[tuckerhines]

how did you decide on 4.56s? I have 4.56s and am worried its too low even with a 4r70w. I guess it depends what tire size you plan to run.

[paulbuoniconti]

What gears did you go to? I am currently finishing up on my 302 beef up and have a good AOD transmission. The 3.55 seem too sluggish and with 33's what do you suggest?

[ChrisGregan]

could have used this video a month ago!

[redneckgearheadgarage]

The radius arms should have got the PC treatment with the frame.

[mroverkill]

"Carl and James are Yukon Gear and Axle Master Installers." I have 2 corrections for that sentence. Carl is the only one master certified, and Mike the correct name

[Kevin]

You posted this more than month early!?!?!?