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Chris Waterman's Jeep/Bronco

 
Introduction
 
Choosing and Prepping the Engine
 
NP435 Transmission and Clutch
 
TCase #1: NP203
 
TCase #2: Dana 20
 
Wiring Harnesses
 
Miscellaneous Bits
 
Doing the Swap!
 
The Butcher's Bill
 
Acknowledgements
 

If you want to contact me, send me an email at
chrisw@bc4x4.com

You can also visit my homepage.

The Butcher's Bill

Here's an itemized and costed list of all the stuff I bought before and during this project.  All prices include any shipping and tax that I paid, and are in $CDN, except the totals, which are in $CDN and $US.
 

Engine:

Item Bought from Price ($CDN)
1990 Mustang 5.0L, complete National Mustang 1425
'90 Mustang oil pump (p/n 224-41118) Lordco 28
'86 F-series starter, rebuilt (Bosch p/n SR595X) Lordco 91
'90 Mustang rebuilt water pump Pacific Parts 36
Head gaskets (Felpro p/n 8548PT2) Pacific Parts 39
Other Fel-pro engine gaskets (oilpan, timing cover, etc) Lordco 75
8 NKG spark plugs Lordco 22
Distributor cap and rotor Lordco 30
'90 Mustang serpentine belt Lordco 27
'89 oil pressure sender (Niehoff p/n DR135S) Lordco 8
'89 coolant temp sender (Niehoff p/n xx) Lordco 8
ARP head bolts for 302 Mopac 62
Ford Motorsports plug wires Mopac 91
K&N cone-type air filter for '90 5.0L Mopac 70
"Ford red" engine enamel Lordco 12
Subtotal: $2024 CDN

Transmission and Clutch:

Item Bought from Price ($CDN)
NP435, with top cover, shifter, and boot Engine Finders 200
Spare NP435 mainshaft, gears, and synchros Engine Finders 50
'86 Ford F-series bellhousing for hyd clutch, w/ fork & boot Ceegee's Parts 100
'86 Ford F-series I6 (300) flywheel, resurfaced Ceegee's Parts 50
Flywheel rebalancing for 302 Cincinatti Balancing 40
'86 Ford F-series clutch slave cylinder Lordco 55
'86 Ford F-250 (>6800 lb) 11" clutch Lordco 230
'86 Ford F-series clutch setup (master, slave, and hose) A-Central Parts 51
'90 Mustang 5.0L/5-spd pilot bearing Lordco 14
NP435 rebuild kit (bearings, seals, gaskets) p/n T127 Lordco 91
NP435 input seal (replacement - doh!) Bert's Automotive 9
Subtotal: $890 CDN

Transfer Case #1 (NP203):

Item Bought from Price ($CDN)
Dodge NP203, gear reduction box only Engine Finders 75
Rebuild parts (bearings, seal) Valley gear 91
NP203 output bearing Bert's Automotive 38
Subtotal: $204 CDN

Transfer Case #2 (D20):

Item Bought from Price ($CDN)
'72 Early Bronco D20, with adapter Ralph's 171
EB D20 rebuild kit (bearings, seals, gaskets) Valley Gear 199
Subtotal: $370 CDN

All the Other Stuff:

Item Bought from Price ($CDN)
Oil filter relocator kit Lordco 75
Speedo cable (p/n CA-3032) Lordco 23
'90 Mustang fuel pump (Federal Mogul p/n P74033) Lordco 153
'90 Mustang fuel filter (FRAM p/n G3802A) Lordco 10
Muffler (Flowmaster p/n 42550) Lordco 104
Catalytic converter (Walker p/n 15142) Lordco 107
Cat conv air tube teflon hose (Walker p/n WAK-35574) Auto Parts Plus 39
Custom adapters (material & shop time) It's a secret 330
'93 YJ 80L gas tank, with skidplate Gary's Autowrecking 75
Fuel injection hose (5/16 & 3/8) Lordco 30
Fuel injection hose clamps (Tridon p/n FI6 & FI4) UAP / Napa 10
NP435 & NP203 shaft rework Moser Engineering 217
Tranny & t-case housing & gear hot-tank & de-rust Redi-Strip 197
Custom exhaust installation Muffler Man 257
'85 Bronco front driveshaft and 1330 9" pinion yoke Engine Finders 75
Driveshaft shortening (both shafts), & one u-joint Driveline Services 125
Fluids (motor oil, gear oil, antifreeze, brake fluid) Lordco 50
Nuts and bolts Acklands/Grainger 40
Hammerite paint, red, 1L General Paint 19
Subtotal: $1936 CDN

The Bottom Line:

I've used 0.67 dollar exchange rate here, since that's what it is at the time I'm writing this.
 
Engine $2024 CDN $1356 US
Tranny and clutch $890 CDN $596 US
Transfer case #1 $204 CDN $137 US
Transfer case #2 $370 CDN $248 US
Other stuff $1936 CDN $1297 US
TOTAL $5424 CDN $3634 US

Recovered Costs:

I did manage to sell some of the parts that came out of the Jeep during the swap:
 
Part Price ($CDN)
AX15 tranny, NP231 t-case w/ Currie SYE 400
York air compressor & brackets 100
4.2L engine 200
4.2L starter, computer, etc 100
TOTAL $800 CDN


 
 
 

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