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Jason Atkinson
Coyote in a Bronco
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BC Broncos
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Story and Photos by Jason Atkinson
We started this project with what was thought to be a nice Bronco. We pulled the body off of the frame, which only took 3 hours then sent it off to be sand blasted. Once we got it back the hard part started, prepping the frame, cutting off 40 years of PO mods, grinding, welding up cracks and truing it. This took 2 days of hard work and then it was back to the powder coater.
Because the customer wanted coil overs we knew we would be cutting the coil buckets and shock mounts off the frame. We were sure we would have to cut off the stock motor mounts and at the least modify the cross member. It would be a great candidate for the Coyote motor but only if we didn’t have to modify the frame and could just bolt in the new Coyote, which is exactly what we did.
We got the new 5.0L Coyote engine a week before we got the Bronco so we started doing some measuring it looked like it would fit but it would be tight. We installed the motor in our mockup frame and realized that we could mount it without cutting the frame.
The real test would be if it would fit in the engine compartment. We had a restoration body and frame that we had just got back from the soda blaster so we dropped it in to see what it looks like from firewall to core support and between the inner fenders. Wow, it was really tight. It looked like we would have to cut the passenger inner fender and move it out ½”.
The Lone Star Bronco Club annual roundup was coming up and we planned to get the engine in the Bronco so we could take it to the event so everyone could see what we were working on. The motor install was a big hit but the rebuild was far from complete.
That Monday we hit it hard and removed the body and started building motor mounts, the serpentine system and headers. We wanted to build these parts in his actual frame so we would be sure it would fit his Bronco. Once we got all of our measurements and some mock up parts built, we pulled the motor and transmission and installed them in our R&D frame while we stripped Chad’s frame and started cutting off the old brackets and building the new shock/coil mounts.
After we got the frame prepped we sent it off to the powder coater; one week later we got the frame back and started installing parts.
The actual build occurred over several months but here it is compressed into the actual fourteen working days.
The first day we cleaned the paint booth so we could build the frame in place and take some great pictures. With the frame on stands, we installed the rear suspension, assembled the rear end and installed the tires.
Day 2 We re-sealed the front end and installed the brakes, radius arms and front end. Then we installed the coilovers and tires - now we had a rolling frame.
Day 3 It was a big day - installed the steering box, mocked up the fuel and return lines, installed the front chrome bypass shocks, tie rod and chrome steering stabilizers. We finished off the day by dropping in the new 2011 Coyote motor and 4R70W transmission. The Atlas2 T-case hadn’t arrived so we would install it after the body was on. We planned to do the 5R55S or the 6R transmission but the controllers weren’t available so we went with the 4R70W transmission. It’s a proven transmission that’s rated for 700 HP.
Day 4 The fuel tank and the in-tank high volume, high-pressure pump were installed and then the fuel lines. We finished off the day by mounting the rear shocks and the bumpers.
Day 5 We built and installed the oil relocation kit. We planned on installing the D20 but the customer upgraded to an Atlas t-case. As a result, we had to pull the transmission, change the adapter and shaft, then we installed the flex plate and mounted the transmission dipstick and wiring for the final time. Lastly, we installed the fuel filler and vent hoses on the fuel tank.
Day 6 We reworked the passenger inner fender and reinstalled it. Then we cut holes on the top of the inner fenders so we could bolt on the rest of the engine cage once we had everything done. We sprayed the engine compartment to have a uniform color match to the existing paint. With the body back on the lift, we rolled the frame under the body.
Day 7 Setting the body on the frame, we then started test fitting and connecting parts like crazy. We mounted the computer and laid out the wiring, mounted the fuel regulator and threaded on the SS fuel lines I built earlier. Lastly, we installed the battery and cables.
Day 8 We removed the mock up serpentine system we designed and installed the production setup. Three guys worked on this serpentine set-up for literally 100 hours and probably another 100 off the books. I was here until midnight and one o’clock in the morning for weeks to get this setup right.
So far this is the only system for the Coyote that will allow you to use the alternator and power steering on the correct side of the engine so you don’t have to cross hoses and wires - including the A/C - without cutting your frame or cross member. Using two spring tensioners, almost all of the parts are replacement Ford parts. This serpentine kit is very compact yet it has nine pulleys with just enough room to run the Taurus electric fan.
Day 9 It was time to mount the drive by wire accelerator peddle, install the Ididit column and lower shaft and then get the fuse/relay box mounted into the under-dash mount and finally mount the OBD 2 test port.
Day 10 We mounted the Atlas 2, twin stick shifters and the Lokar 4R70W shifter and boots. We also mounted the PCS transmission controller computer and wired it.
Day 11 After mounting the radiator, electric fan and custom radiator hoses, we also mounted the power steering reservoir and built and installed the lines and hoses. We also installed the radiator over flow bottle and ran the hoses to the oil filter.
Day 12 Once the drive shafts were installed, we took the Bronco to the exhaust shop and had a two into one exhaust and Magnaflow muffler installed. At first glance it looks just like our BC Bronco 2X2.5” in and 1X3” out exhaust but the headers dump out in a different location.
Day 13 We installed the engine cover, new engine cross over support and the power brake unit for the last time. We also installed the air intake hose and filter.
Day 14 It was the big day. Time to wire up the last connections and add all of the fluids. I hit the key to prime the fuel system and before I could get my hand off the key it started. Without hours of testing wire connections, pumping up oil pressure, adjusting timing or breaking in cams - it just started and idled in an instant.
It sounds awesome, if you want to hear it and see some test videos go to BC Broncos home page and click the You Tube channel link to check them out. When we have all of the parts available for sale you will be able to just bolt in the new Coyote 5.0L
Here is a breakdown of what you will need to install a Coyote in your Bronco and why. We are building parts and kits to fix all of these issues or you can build your own.
A transmission because the Coyote bell housing is the same as the modular motors so the stock transmission will not work. At this time, you only have three choices and they are all automatics - the 4 speed 4R70W (they made 2 versions small block and modular), the 5 speed 5R55S and 6 speed 6R. Right now they are working on the t-case adapters for the 5 and 6 speed manual transmissions.
A radiator that has the outlets switched from side to side i.e. 5.0L. The stock upper hose on the Coyote is angled to the right, if you go to the left, there’s no room for the air intake.
One-inch body lift if you want to use the upper 5.0L engine cover. The cover hides the heater hoses, A/C hoses and fuel lines.
A steering column - we used the IDIDIT column because it is shorter and is 2” in diameter (stock is 2.25”) and we used the smaller Borgeson U-joints instead of the rag joint. The column is very close to the Coyote valve cover so every little bit helps and it did.
A serpentine system - the engine only comes with a water pump and crank pulley. If you want to install this motor without cutting or modifying the frame you will need the BC Broncos serpentine system, even if you don’t want power steering or A/C. The stock Coyote alternator sits low on the left so you will need to cut the frame right at the track bar mount and cross member.
Headers - you cannot use the stock Coyote headers, as both sides will hit the frame, the passenger will also hit the floor and inner fender. If you send us your headers we can modify them to fit.
Oil relocation kit - the stock oil filter hits the frame so you will need to move it.
Motor mounts - you will need to build adapter motor mounts to bolt the motor to the frame, or you can cut the frame mounts off and start from scratch. We built a set of motor mounts so you don’t have to cut your frame and they feature replaceable rubber mounts.
Air filter - you will need an air filter and intake hose.
The Brakes are very close to the valve cover, you can modify the stock power brakes or use a few versions of hydro boost.
Good luck and enjoy it.