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1992-1996 Ford Bronco Repair Manual

Ford Bronco repair manualsThe fifth generation Ford Bronco was introduced in 1992 in a 3-door station wagon body style. Four trim levels were available: base, XL, XLT and Eddie Bauer. 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: 183.6 in (4,660 mm); Width: 79.1 in (2,010 mm); Height: 74.5 in (1,890 mm) [1992-1994], 74.4 in (1,890 mm) [1995-1996].

1992-1996 Ford Bronco 3-door station wagon

1992-1996 Ford Bronco 3-door station wagon

1992-1996 Ford Bronco XLT

1992-1996 Ford Bronco XLT

4.9L Ford 302 V8 engine

4.9L Ford 302 V8 engine

5.8L Ford Windsor V8 engine

5.8L Ford Windsor V8 engine

4-speed E4OD automatic transmission

4-speed E4OD automatic transmission

5-speed M5OD-R2 manual 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 Windsor OHV V8 produced 210 hp (157 kW) and 315 lb·ft (427 N·m) [1992], 200 hp (149 kW) and 310 lb·ft (420 N·m) [1993], 240 hp (179 kW) and 340 lb·ft (461 N·m) [1993-1995], 210 hp (157 kW) and 325 lb·ft (441 N·m) [1994-1996]
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: pushrod OHV; Compression ratio: 8.0:1; Supercharger: naturally aspirated; Fuel system: EFI; 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:
4-speed Ford AOD-E overdrive automatic transmission with electronic shift solenoids
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
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.
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 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 BW1356 transfer case
General information: Low-range ratio: 2.69:1; Low-range: 1.00:1; Case Material: magnesium, two piece; Shift Type: manual and electric shift versions produced; Fluid Type: MERCON ATF; Fluid Capacity: 2 quarts capacity; Identification: Metal tag stamped with “1356” located on transfer case, typically on the backside. Magnesium, ribbed, two piece transfer case (two part casting bolted together in the center).
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 1992-1996 Ford Bronco repair manuals are written specifically for the do-it-yourselfer.

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