1994 Ford Bronco 4x4 Truck - Vehicle Feature

What if you only had one truck? What if that truck had to do it all: commuting, camping, prerunning, and trail riding? What if you didn't have a ton of cash to spend to purchase that truck? If this list of what-ifs describes your situation, we think you should take a good, hard look at an '80-'96 fullsize Ford Bronco.

Even in humble stock trim, the Bronco has a lot to offer. Built on a strong body-on-frame platform, the Bronco has room for five people and cargo space for plenty of gear. The removable hardtop offers occupants shelter from the elements and lockable storage space. Engine choices are solid and proven: Ford's 300ci inline-six, the 302 V8, and the 351 Windsor V8. Transmission choices include the heavy-duty C6 three-speed, the four-speed AOD, and finally, the electronically controlled E4OD four-speed. The Borg-Warner 1356 T-case remained in place throughout the Bronco's 16-year production span. Rear axles include the legendary Ford 9-inch and Ford's 8.8. The Twin-Traction Beam front suspension combines the ruggedness of a solid axle with the superior ride quality of IFS. A high-pinion Dana 44 third member bolts into place on the driver-side traction beam. There's a lot to like.

Lee Hayes wanted a do-it-all truck when he had the opportunity to go prerunning in Baja with famous fast guy, Curt LeDuc. "I had a different truck in mind, but after riding in Curt's Bronco I decided that that was the way to go," Lee offers. "Curt gave me a price and said that he'd have the work done in 90 days. That was all it took."

Lee rounded up a '94 Bronco from a private party, made the purchase, and delivered his new prize to Curt's shop, California Pre-Fun. Ninety days and some cash later, Lee's new Bronco was transformed into the off-road equivalent of a Swiss Army knife. California Pre-Fun's transformation included front and rear long-travel coilover suspensions, a full bumper-to-bumper rollcage, a trio of MasterCraft PreRun seats, and a full-floating Sandy Cone Ford 9-inch rearend. The Dana 44 third member up front was fitted with 4.88 gears and a limited-slip differential, while the 9-inch's Strange nodular-iron third member got a matching ring-and-pinion ratio, forty-spline axleshafts, and a spool.

A rollcage should be strong and protective, but it shouldn't crowd the occupants. To this end, the sheetmetal was trimmed back so the tubes could be tucked behind it, then the sheet and tube were welded together. This construction method also eliminates a ton of squeaks and rattles.
A rollcage should be strong and protective, but it shouldn't crowd the occupants. To this
A pair of Hella lights hides behind the protection of a bumper/skidplate combo.
Ordinarily, we don't snap photos of A/C equipment, but a functional A/C system is one of this truck's coolest features. We mean that literally and figuratively. The A/C system is normally hidden behind a Boatec fiberglass fender and beneath a Hannemann fiberglass hood.
Ordinarily, we don't snap photos of A/C equipment, but a functional A/C system is one of t

The stock rear bench seat is just too big and unsecure for the speeds and terrain this Bronco is capable of reaching. A MasterCraft PreRun seat and matching five-point harness were wisely bolted in its place. The view is great from the third seat.
The stock rear bench seat is just too big and unsecure for the speeds and terrain this Bro
Remember the cargo space we mentioned? Here it is. Yes, you can haul plenty of gear in a pickup bed, but it won't be protected from rain and dust and sticky fingers.
Remember the cargo space we mentioned? Here it is. Yes, you can haul plenty of gear in a
Lee's Bronco lashes, bolts, and straps down the gear to keep it in place during low-altitude strafing runs.
Lee's Bronco lashes, bolts, and straps down the gear to keep it in place during low-altitu

Removed for this photo, a pair of bulged Autofab fiberglass quarter-panels envelops the 35-inch Toyo Open Country M/Ts on 17-inch Ultra wheels beadlocked using Champion rings. The rear wheels spin on a pair of Sandy Cone floater hubs. Fully floating rearends let the wheels bolt toa pair of hubs instead of directly to a flanged axleshaft.
Removed for this photo, a pair of bulged Autofab fiberglass quarter-panels envelops the 35
The floating hubs are turned by a pair of axleshafts. Since the hubs support the vehicle weight and not the axleshafts, the 'shafts only need to turn the hubs. Dividing the weight-bearing and vehicle-moving jobs means that if a 'shaft breaks, the wheel stays securely attached to the housing. Behind the Ultra wheels, Wilwood Superlite II calipers bring things to a halt when needed.
The floating hubs are turned by a pair of axleshafts. Since the hubs support the vehicle
When it comes to air filters, bigger is better, and UMP air filters are some of the biggest we've seen to date. Cal Pre-Fun's 'cage work not only integrates structural reinforcement and shock mounts, it also provides attachment points for everything from the radiator to the fuse box to the battery tray to the hood pins.
When it comes to air filters, bigger is better, and UMP air filters are some of the bigges

The buildup finished off with a color transformation via the talents of George Reiss. Reiss used ultra-tough white and silver hues of Endura epoxy paint. DuPont Kevlar graphics run along the border between the Endura white and silver.

This truck gets driven - hard. "Each year, I go prerunning with Curt for the Baja 1000. We do three preruns. The first is to travel the route and familiarize ourselves with the course in general. The second time, we check out the course and decide which lines are the best. The third and final time, we run the course using the lines we've settled on for race day," Hayes reports.

Between Baja trips, the Bronco does frequent weekend duty at the Ocotillo Wells OHV area and as a chase truck for Fabtech's 1450-class Toyota built and driven by Shawn Giordano.

Lee Hayes works as hard as he plays. He owns A&L Litho, a printing business based in Escondido, California. The company offers prepress services, printing presses for any-size job, and binding and finishing services once the printing is done. Owning a business is not a "spare time" hobby. Business ownership typically requires beyond-overtime hours, cash flow for paying bills, and skilled customer service. What's the reward? "I own my own business so that I can make enough money to go play in the desert."

After crawling under, over, and riding in this off-road multitool, the Bronco's popularity rang loud and clear in our craniums. We gobbled up nasty whoops, sliced through the sand, and generally did our best to defy friction and gravity, and we did it all while the audio system pelted our ears and the air conditioner kept us cool. If you need one truck that can do it all, check out a Bronco. It's one of the most versatile off-road trucks ever made.

The high-pinion Dana 44 front differential was used on the front of Ford 1/2-ton 4x4s from '62 all the way to '96. The high-pinion design offers increased strength in a front- axle application and has better ground clearance. The front end spins on a 4.88 ring-and-pinion set wrapped around a limited-slip differential.
The high-pinion Dana 44 front differential was used on the front of Ford 1/2-ton 4x4s from
The leaf-spring rear suspension was deleted to make way for a Cal Pre-Fun three-link. The upper and lower links pivot on a combination of Delrin bushings and Heim joints for smooth action and off-road durability...
The leaf-spring rear suspension was deleted to make way for a Cal Pre-Fun three-link. The
The Ford 8.8 rearend was also ditched and replaced with a trussed and tabbed Ford 9-inch rearend by Sandy Cone. Richmond Gear supplied the 4.88 ring-and-pinion set as well as the spool it's bolted to...
The Ford 8.8 rearend was also ditched and replaced with a trussed and tabbed Ford 9-inch r

A pair of 3-inch-diameter, 16-inch-stroke King shocks suspends and damps the tail section's range of motion.
A pair of 3-inch-diameter, 16-inch-stroke King shocks suspends and damps the tail section'
A quartet of Hella HIDs. All the better to see you (and everything else) with.
This brace ties the front and rear suspensions together. Curt LeDuc used 4130 tube and plate throughout.
This brace ties the front and rear suspensions together. Curt LeDuc used 4130 tube and pl

Ford's stock steering leaves quite a bit to be desired. In stock trim, the driver-side Traction Beam is much longer than its corresponding tie rod. This causes bumpsteer. The stock tie rods are also pretty skinny. Curt took care of both OEM problems by building this swing-set steering kit. The passenger-side tie rod is driven directly by the pitman arm and also drives a relay rod. The relay rod pushes and pulls on a swing-set arm that in turn drives the driver-side tie rod. The whole system is assisted by a hydraulic ram that pushes and pulls in sync with the power steering box. The ram is partially hidden behind the relay rod.
Ford's stock steering leaves quite a bit to be desired. In stock trim, the driver-side Tr
The radius arms are welded to the Traction Beam housings for strength and simplicity. Check out the bumpstop pad built into the arm-to-beam gusset. The driver-side beam was extensively gusseted and plated. Three-inch-diameter, fourteen-inch-stroke King coilovers net 16 inches of front travel with fully functioning four-wheel drive. To maintain the suspension, the front end gets new bushings and Heims about once a year, and the rear end gets the same treatment twice a year. Since these suspensions endure thousands of miles of severe use, regular replacement intervals are the best way to ensure being able to drive home after each Baja prerun.
The radius arms are welded to the Traction Beam housings for strength and simplicity. Che