1980-1986 Ford Bronco Repair Manual
The third generation Ford Bronco was introduced in 1980 in a 3-door station wagon body style. Three trim levels were available: base, XL and top trim XLT.
General information: Class: full-size SUV; Body style: 3-door station wagon; Layout: front engine, four-wheel drive; Wheelbase: 104.0 in (2,642 mm); Length: 180.4 in (4,582 mm); Width: 79.3 in (2,014 mm); Height: 75.5 in (1,918 mm).
 1980-1986 Ford Bronco 3-door station wagon  4.9L Ford 302 V8 engine  5.8L Ford 351M V8 engine  3-speed C6 automatic transmission  4-speed Borg-Warner T-18 manual transmission  4-speed New Process NP435 manual transmission |
Engines:
4.9L Straight-6 produced 122 hp (91 kW) at 4,400 rpm and 260 lb·ft (353 N·m) of torque at 2,400 rpm
General information: Configuration: I6; Displacement: 300 cu in (4,916 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 3.98 in (101.1 mm); Fuel system: normally aspirated, carburettor.
4.9L Ford 302 OHV V8 produced 290 hp (216 kW) at 5,200 rpm and 290 lb·ft (393 N·m) of torque at 4,300 rpm
General information: Configuration: 90° OHV small-block V8, 4.380 in bore spacing; Displacement: 302 cu in (4,948 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: 8.0:1.
5.8L Ford 351M OHV V8 produced 156 hp (115 kW) and 262 lb·ft (355 N·m) [1977-1978], 158 hp (116 kW) and 262 lb·ft (355 N·m) [1979]
General information: Configuration: 90° OHV small-block V8, 4.380 in bore spacing; Displacement: 351 cu in (5,752 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 3.5 in (88.9 mm); Cylinder block alloy: Cast iron; Cylinder head alloy: Cast iron ; Valvetrain: Overhead valve; Compression ratio: 8.8:1.
5.8L Ford Windsor OHV V8 produced 153-161 hp (114-120 kW) at 3,600 rpm and 330 lb·ft (447 N·m) of torque at 2,600 rpm
General information: Configuration: 90° OHV small-block V8, 4.380 in bore spacing; Displacement: 351 cu in (5,752 cc); Cylinder bore: 4.0 in (101.6 mm); Piston stroke: 3.5 in (88.9 mm); Cylinder block alloy: Cast iron; Cylinder head alloy: Cast iron ; Valvetrain: Overhead valve; Compression ratio: 8.8:1.
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 C6 automatic transmission
Gear ratios (overall): I – 2.46:1; II – 1.46:1; III – 1.0:1; R – 2.18:1
4-speed Ford AOD overdrive automatic transmission
Gear ratios (overall): I – 2.40:1; II – 1.47:1; III – 1.00:1; IV – 0.67:1; R – 2.00:1
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.
4-speed Borg-Warner T18 manual transmission
Gear ratios (overall): I – 4.02:1; II – 2.41:1; III – 1.41:1; IV – 1.0:1; R – 4.73:1
4-speed New Process NP435 manual transmission
Gear ratios (overall): I – 6.69:1; II – 3.34:1; III – 1.79:1; IV – 1.0:1; R – 8.26:1
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:
Borg Warner BW1345 transfer case
General information: Low-range ratio: 2.72:1; High-range: 1.0:1; Case Material: aluminum, two piece; Shift Type: manual; Fluid Type: DEXTRON II ATF; Identification: Small metal tag, usually on back side of transfer case, has model “1345” stamped into it. Case is aluminum, ribbed, and can be split down the middle (two piece casting).
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 1980-1986 Ford Bronco repair manuals are written specifically for the do-it-yourselfer.
