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1965-1977 Ford Bronco Repair Manual

1965-1977 Ford BroncoThe first generation Ford Bronco was introduced in 1965 in three body styles: 3-door station wagon, 2-door pickup and 0-door roadster. General information: Class: compact SUV; Layout: front engine, four-wheel drive; Wheelbase: 92.0 in (2,337 mm); Length: 151.5 in (3,848 mm); Width: 68.5 in (1,740 mm); Height: 71.6 in (1,819 mm).

Engines
2.8L Straight-6 produced 105 hp (78 kW) at 4,400 rpm and 156 lb·ft (212 N·m) of torque at 2,400 rpm
General information: Configuration: I6; Displacement: 170 cu in (2,781 cc); Cylinder bore: 3.50 in (89.0 mm); Piston stroke: 2.94 in (75.0 mm); Compression ratio: 9.1:1.
3.3L Straight-6 produced 105 hp (78 kW) at 4,400 rpm and 156 lb·ft (212 N·m) of torque at 2,400 rpm
General information: Configuration: I6; Displacement: 200 cu in (3,277 cc); Cylinder bore: 3.685 in (93.6 mm); Piston stroke: 3.126 in (79.4 mm); Compression ratio: 9.1:1.
4.7L Windsor OHV V8 produced 195 hp (145 kW) at 4,400 rpm and 258 lb·ft (350 N·m) of torque at 2,200 rpm
General information: Configuration: 90° OHV small-block V8, 4.380 in bore spacing; Displacement: 289 cu in (4,736 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 2.87 in (72.9 mm); Cylinder block alloy: cast iron; Cylinder head alloy: cast iron; Valvetrain: pushrod OHV; Compression ratio: 8.8:1; Supercharger: naturally aspirated; Fuel system: Carbureted; Fuel type: gasoline; Oil system: Wet sump; Cooling system: Jacketed block.
4.9L Windsor OHV V8 produced 210 hp (157 kW) at 4,600 rpm and 300 lb·ft (407 N·m) of torque at 2,600 rpm
General information: Configuration: 90° OHV small-block V8, 4.380 in bore spacing; Displacement: 300 cu in (4,916 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 3.0 in (76.2 mm); Cylinder block alloy: cast iron; Cylinder head alloy: cast iron; Valvetrain: pushrod OHV; Compression ratio: 9.0:1; Supercharger: naturally aspirated; Fuel system: Carbureted; Fuel type: gasoline; Oil system: Wet sump; Cooling system: Jacketed block.
Repair operations: repair operations possible with the engine in the vehicle; intake manifold: removal and installation; exhaust manifold: removal and installation; valve covers: removal and installation; cylinder head: removal, inspection and installation; engine: removal and installation; engine block: cleaning and inspection; spark plug thread repair; timing chain wear: check; timing cover and timing chain: removal and installation; oil pump: removal, inspection and installation; oil pan: removal, inspection and installation; camshaft and lifters: removal, inspection and installation; crankshaft: inspection, removal and installation etc.
Transmissions
3-speed Ford C4 automatic transmission
Gear ratios (overall): I – 2.46:1; II – 1.46:1; III – 1.0:1; R – 2.18:1
Repair operations: manual shift linkage: inspection, removal, installation and adjustment; throttle valve mechanisms: removal, installation and adjustment; kickdown mechanisms: removal, installation and adjustment; vacuum modulator: check and replacement; band adjustment; automatic transmission: removal and installation; electronic shift transmission: general information; manual lever position sensor: adjustment; neutral start switch: adjustment.
3-speed Ford 3.03 manual transmission
Gear ratios (overall): I – 3.41:1; II – 1.86:1; III – 1.1:1; R – 2.42:1
Repair operations: shift linkage adjustment; shift lever: removal and installation; transmission mounts: check and replacement; manual transmission: removal and installation; speedometer pinion gear and seal: replacement; extension housing oil seal: replacement.
Transfer Case
Dana 20 transfer case
General information: Low-range ratio: 2.46:1; High-range: 1.00:1; Case Material: cast iron; Shift Type: manual; Shift pattern: 2WD-4HI-N-4LO; Fluid Type: OEM fluid requirements varied, 80w-90 gear oil is typical; Fluid Capacity: 2.75 pints (1.375 quarts).
Repair operations: transfer case: removal and installation; transfer case: overhaul; front output shaft oil seal: removal and replacement; rear output shaft oil seal: removal and replacement; rear extension housing bushing: removal and replacement; manual shift lever assembly: removal and installation; electronic shift: removal and installation.
Other manuals: cooling, heating and air conditioning systems; fuel and exhaust systems; engine electrical systems; emissions and engine control systems; driveline; brakes; suspension and steering systems; body; chassis electrical system; wiring diagrams. All 1965-1977 Ford Bronco repair manuals are written specifically for the do-it-yourselfer.

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