Generation:
Fifth Generation (1980-1996)
Model Years Covered:
1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Chassis Code:
U150 (This generation represents a significant redesign from previous Bronco generations, often considered to have distinct chassis codes within the overall U-series designation)
Target Audience:
DIY enthusiasts, professional automotive technicians, Ford Bronco owners seeking detailed repair and maintenance information.
Advantage:
Provides the most reliable information, comparable to authorized dealer service departments, enabling users to perform repairs like a professional.
Purpose:
To help owners get the best value from their Ford Bronco by enabling informed and knowledgeable repairs.
Value Proposition:
Saves money by avoiding expensive shop labor and overhead, empowering owners to perform maintenance and repairs themselves.
Safety Emphasis:
Highlights the importance of using safety equipment and observing precautions, including the use of torque wrenches.
Powertrain:
Engine mechanical (including disassembly and reassembly), fuel system, ignition system, exhaust system, lubrication system, cooling system
Drivetrain:
Transmission (manual and automatic), transfer case, drivelines, axles, differentials
Chassis:
Suspension (front and rear), steering system, braking system (including ABS if applicable to later models)
Electrical:
Wiring diagrams, lighting, instrumentation, charging system, starting system, accessories, power distribution
Body:
Body panels, interior trim, doors, windows, seats, climate control system (HVAC)
Climate Control:
HVAC system (heating, ventilation, and air conditioning) servicing, including refrigerant handling (for models with AC), blower motor, evaporator, condenser, and ducting.
Fuel System Details:
In-depth coverage of fuel pumps, fuel lines, fuel filters, fuel injectors (for EFI models), fuel tanks, and emission control systems.
Cooling System:
Radiator, water pump, thermostat, heater core, hoses, and fan clutch servicing and replacement.
Routine Maintenance:
Tune-ups, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and adjustment
Repair And Overhaul:
Engine overhaul, transmission rebuild, brake caliper/rotor replacement, steering component replacement, suspension component replacement, electrical component troubleshooting and repair
Diagnostics:
Troubleshooting common issues, diagnostic flowcharts, symptom-based repairs
Removal And Installation:
Detailed step-by-step procedures for removing and installing major and minor components
Assemblies And Disassemblies:
Complete breakdown and reassembly of various vehicle systems and components
Depth Of Coverage:
Comprehensive, assuming general automotive knowledge, with emphasis on specific Bronco aspects. Covers everything from routine maintenance to complete engine and transmission overhauls.
Special Tools:
The manual mentions recommended or required special tools, often identified by Ford part numbers, for specific adjustments or repairs.
Engine Options:
This manual likely covers the commonly available engines for the 1980-1995 Ford Bronco, which typically included inline-6 and V8 configurations. Specific engine displacements varied by year and model. Likely candidates include: 4.2L (255 cu in) V8, 4.9L (300 cu in) I6, 5.0L (302 cu in) V8, 5.8L (351 cu in) V8 Windsor, and the legendary 5.8L (351 cu in) V8 Cleveland for some earlier models in the range.
Inline 6 Engine:
The 4.9L (300 cu in) inline-6 engine was a workhorse, known for its torque and durability, often found in base models and trucks from this era.
V8 Engine Options:
The 5.0L (302 cu in) and 5.8L (351 cu in) Windsor V8 engines offered increasing levels of power and performance, making them popular choices for those seeking more capability.
Horsepower Torque:
Horsepower and torque figures varied significantly by engine and model year. For example, the 5.0L V8 in the early 1980s might have produced around 156 hp and 240 lb-ft of torque, while later 5.8L V8s could exceed 200 hp and 300 lb-ft of torque. The manual would detail specific figures for each engine variant.
Engine Management:
Carbureted systems for earlier models; electronic engine control (EEC-IV or later) for fuel-injected models, managing ignition timing, fuel delivery, and emissions.
Fuel Delivery:
Early models would feature carbureted fuel systems (e.g., Ford's 2-barrel or 4-barrel carburetors). Later models, especially from the late 1980s onwards, would incorporate Electronic Fuel Injection (EFI), including Multi-Port Fuel Injection (MPFI) on some V8 engines.
Standard Transmission:
Manual transmissions were common, often a 3-speed or 4-speed manual. Overdrive units became more prevalent in later years for improved fuel economy.
Optional Transmission:
Automatic transmissions were widely available and highly popular, typically Ford's C6 (3-speed heavy-duty automatic) or the AOD (4-speed automatic overdrive).
Transfer Case:
Four-wheel drive (4WD) was a defining feature. The manual would cover the operation and servicing of various transfer case options, likely including manual shift (e.g., NP205, NP208) and potentially electronic shift-on-the-fly (ESOF) systems in later years.
Gear Ratios:
The manual would detail specific gear ratios for both manual and automatic transmissions, as well as transfer case low-range ratios, crucial for off-road performance.
Wheelbase:
The fifth generation Bronco typically featured a 104.7-inch wheelbase. Body styles included a two-door SUV.
Length:
Approximate length around 174-180 inches, varying slightly by model year and configuration.
Width:
Approximate width around 79 inches.
Height:
Approximate height around 67-70 inches.
Curb Weight:
Curb weight typically ranged from 3,800 to 4,500 lbs, depending on engine, transmission, and equipment.
Crash Testing:
This era of vehicles predates the stringent modern crash testing standards. While specific ratings might not be readily available, the manual would cover safety systems present at the time, such as seat belts and rudimentary crumple zones. The manual's focus is on repair and maintenance, not safety ratings themselves.
Braking System:
Front disc brakes were standard across the range. Rear drum brakes were common, though rear disc brakes might have been optional or standard on higher trims in later years. Some later models may have featured ABS as an option.
Seat Belts:
Front and rear seat belts, typically lap and shoulder belts for front occupants and lap belts for rear occupants.
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months, depending on driving conditions. The manual would specify exact intervals and recommended oil types based on engine.
Transmission Fluid Change:
Automatic transmission fluid and filter changes were often recommended every 30,000-60,000 miles. Manual transmission fluid checks and changes would also be covered.
Engine Oil:
The manual would specify SAE viscosity grades (e.g., 5W-30, 10W-30) and API service classifications suitable for each engine, with specific capacity in quarts (e.g., 5 quarts for a 302 V8 with filter change).
Coolant:
A mixture of antifreeze and distilled water, typically a 50/50 ratio. The manual would specify the type of antifreeze (e.g., ethylene glycol) and the total cooling system capacity.
Brake Fluid:
DOT 3 brake fluid was commonly specified. Capacity would be for the brake master cylinder reservoir.
Power Steering Fluid:
Specific power steering fluid type, often Dexron-type ATF, would be detailed. Capacity would be for the power steering reservoir.
Manual Transmission Fluid:
Specific gear oil viscosity and API classification (e.g., GL-4 or GL-5) would be detailed for manual transmissions.
Automatic Transmission Fluid:
Mercon or Dexron II/III ATF was commonly specified for automatic transmissions.
Differential Fluid:
Hypoid gear oil (e.g., SAE 90) with limited-slip additive if equipped with a locking differential would be specified for front and rear axles.
Common Wear Items:
As a vehicle from this era, common issues would involve wear and tear on suspension components (bushings, ball joints, tie rods), exhaust system rust, fuel system components (fuel pumps, injectors), ignition system components (distributor, coil), and potential leaks from engine or transmission seals.
Body Corrosion:
Rust and corrosion, particularly in areas exposed to road salt or moisture, were prevalent issues for vehicles of this vintage. Body repair procedures would be crucial.
Electrical Gremlins:
Aging wiring harnesses, corroded connectors, and failing switches could lead to intermittent electrical problems. The comprehensive electrical diagrams in the manual would be invaluable.
Ford SUV Legacy:
The Ford Bronco has a storied history as one of the original American SUVs, known for its ruggedness, off-road capability, and versatility, dating back to the mid-1960s. The 1980-1996 generation represented a significant evolution towards a more modern, refined, yet still capable off-road vehicle.
Fifth Gen Changes:
The 1980 model year saw a complete redesign from the previous generation. This Bronco moved to a coil-spring front suspension for improved ride quality and handling, and a new chassis shared with the Ford F-150 pickup truck. Aerodynamic improvements and updated styling were also key features. Later years saw gradual updates to engines, transmissions, interior features, and safety equipment.
Design Philosophy:
This generation represented a shift towards a more integrated chassis design, bridging the gap between traditional body-on-frame SUVs and the emerging trend of more car-like SUVs, while retaining robust off-road capabilities.
Manufacturing Locations:
Ford Bronco vehicles of this era were primarily manufactured in the United States.
