1987-1991 Ford Bronco Repair Manual
The fourth generation Ford Bronco was introduced in 1987 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: 104.7 in (2,660 mm); Length: 180.5 in (4,580 mm); Width: 79.1 in (2,010 mm); Height: 74.0 in (1,880 mm) [1987-1989], 74.5 in (1,890 mm) [1990-1991].
 1987-1991 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 E4OD automatic transmission  5-speed M5OD-R2 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 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; 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.
General engine overhaul procedures: engine overhaul: disassembly sequence, general information and reassembly sequence; engine rebuilding alternatives; engine removal: methods and precautions; camshaft and bearings: inspection; crankshaft: inspection, removal, installation and main bearing oil clearance check; cylinder compression check; cylinder head: cleaning, inspection, disassembly and reassembly; cylinder honing; engine: removal and installation; engine block: cleaning and inspection; initial start-up and break-in after overhaul; main and connecting rod bearings: inspection; oil pump: inspection; piston rings: installation; piston/connecting rod assembly: removal, inspection and installation; timing chain/sprockets or gears: wear checks; valve adjustment and servicing; valve lifters and pushrods: inspection.
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
4-speed Ford E4OD overdrive automatic transmission
Gear ratios (overall): I – 2.71:1; II – 1.54:1; III – 1.00:1; IV – 0.71:1; R – 2.18:1
5-speed Mazda M5OD-R2 manual transmission
Gear ratios (overall): I – 3.90:1; II – 2.25:1; III – 1.49:1; IV – 1.0:1; V – 0.8:1; R – 3.39:1
Repair operations: 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; manual transmission: removal and installation; electronic shift transmission: general information; manual lever position sensor: adjustment; neutral start switch: adjustment etc.
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 1987-1991 Ford Bronco repair manuals are written specifically for the do-it-yourselfer.
