Why didn't Ford build a diesel-powered Bronco? General Motors built thousands of 6.2L- and 6.5L-powered Blazers and Tahoes, while Ford opted to stay out of the 1/2-ton diesel market. Why? Probably because the diesel engines Ford had in its arsenal were extreme-duty heavy-truck engines, the complete opposite of the light-weight motors that GM built at the time. That doesn't mean an enthusiast can't rectify Ford's oversight though. David Calderon of San Diego, California, didn't set out to build two diesel Broncos, but that's what he ended up with. The black '93 Bronco seen here has a 7.3L Power Stroke that he got out of a wrecked '02 Ford Super Duty. The white '93 Bronco received a 6.0L Power Stroke from an '06 Ford Super Duty. Calderon began the dieselfication of his black Bronco eight months ago, yet before he even completed the 7.3L Bronco swap, he tracked down a wrecked '06 6.0L-powered Super Duty to begin transforming the white Bronco as well. We met up with David at Diesel Tech in San Jacinto, California, to take a look at both of his Broncos up close. He showed us that besides swapping diesel engines and transmissions into his two Broncos, he also bolted in the 1-ton axles, transfer cases, and suspension components from the two wrecked trucks that donated the engines. Check them out. 7.3L Powerstroke 7.3L vs. 6.0L Power StrokeBefore David Calderon showed us both of his Broncos, we thought that the 7.3L Power Stroke was the only way to go for a swap like this. The 7.3L Power Stroke is lighter (983 pounds) than the 6.0L (1,005 pounds), but the 6.0L appears to be a tighter package, and therefore seems to free up more room in the engine compartment. David also told us he thought the 6.0L truck was significantly more responsive than the 7.3L. 6.0L Powerstroke The 7.3L is a less complicated engine, so that's the way we'd go if we wanted a diesel Bronco that would last us 500,000 miles. Yet if we were building a Bronco to race, the 6.0L Power Stroke gets the nod. Ultimately, we'd go with whichever engine we could get with the complete donor vehicle for a good price. Both engines will lead an easier life in a 1/2-ton Bronco than in the 1-ton trucks they were designed for. David's swap was complicated somewhat by the fact that the donor engine, intercooler, and wiring harness came from an '02 Ford F-250 Super Duty. You'll notice from the photos that the 7.3L was pushed forward on custom-built motor mounts to gain firewall clearance for the turbocharger and exhaust downpipe. This required David to ditch the mechanical cooling fan in exchange for a large electric version. David's swap was complicated somewhat by the fact that the donor engine, intercooler, and The 7.3L Power Stoke was significantly bigger than the 5.8L 351 Windsor engine that came in these Broncos. In order to handle the extra 500 pounds of weight, David chose to fit the Bronco with the leaf-sprung suspension from the '02 Super Duty donor vehicle. The 7.3L Power Stoke was significantly bigger than the 5.8L 351 Windsor engine that came i Beginning with the '02 model year, all Super Duty trucks came from the factory with a Dana 60 front axle, so that's what David swapped into the front of his 7.3L Bronco. Fitted with 3.73 gears, the 1-ton axle was far better suited to handle the weight and torque than the original 3.55-geared Dana 44 Twin-Traction Beam (TTB) axle. Beginning with the '02 model year, all Super Duty trucks came from the factory with a Dana The front Dana 60 axle was bolted to the Bronco with stock Super Duty leaf springs and hangers. The rear shackles were adapted to the frame with fabricated steel mounts. From this angle, you can also see how the Bronco's E4OD transmission was replaced by a Super Duty 4R100 transmission. The front Dana 60 axle was bolted to the Bronco with stock Super Duty leaf springs and han The original E4OD Bronco transmission crossmember and skidplates were reused, and the Super Duty front driveshaft was bolted into place. The original E4OD Bronco transmission crossmember and skidplates were reused, and the Supe The Bronco's BorgWarner transfer case was replaced with the NV273 transfer case from the donor Super Duty. This allowed David to bolt in a shortened rear driveshaft from the Super Duty, and connect it to the Ford 10 1/2-inch rear axle that replaced the original Ford 8.8-inch rear end. The Bronco's BorgWarner transfer case was replaced with the NV273 transfer case from the d Since Broncos and Super Dutys both use 3-inch-wide leaf springs, the 10 1/2-inch Super Duty rear axle was bolted into the Bronco using factory Super Duty leaf springs and Bronco shackle mounts. The factory fuel tank was retained, but modified with the diesel fuel filler hose from the Super Duty. Since Broncos and Super Dutys both use 3-inch-wide leaf springs, the 10 1/2-inch Super Dut Wiring the Bronco for the diesel engine was simplified by transferring almost the entire wiring harness from the donor Super Duty. If you look closely, you'll notice that the Super Duty gauge cluster was grafted in behind the factory Bronco dash. Wiring the Bronco for the diesel engine was simplified by transferring almost the entire w As crazy as this is going to sound, swapping the 6.0L into a Bronco seems to be easier than fitting in the 7.3L. David reported that thanks to the 6.0L turbo location, there was significantly more room for the exhaust downpipe and turbo. No modifications to the firewall were required, and the engine position provided enough room to reuse the '06 donor truck's radiator, intercooler, and mechanical cooling fan. As crazy as this is going to sound, swapping the 6.0L into a Bronco seems to be easier tha Both Broncos were upgraded with the brake master cylinder and hydroboost brake booster from their Super Duty donor trucks. You'll also notice that David took the time to add an Edge Juice performance module (foreground) to his Broncos. Both Broncos were upgraded with the brake master cylinder and hydroboost brake booster fro Fitting the '06 Dana 60 front axle proved to be a little more involved than swapping the leaf-sprung axle in, but David said the ride improvement made the effort worthwhile. Like the '02 Dana 60 in his 7.3L Bronco, the '06 Super Duty Dana 60 was also fitted with 3.73 gears, but unlike the '02 axle, it was mounted with coil springs and radius arms. Unfortunately, the radius arms on the Bronco were not compatible with the Super Duty axle, so David used a combination of Fabtech radius arms, coil springs, and sway-bar end links to install it. New mounts for the track bar, sway bar, and coil-spring buckets were built. An '06 Super Duty steering box was also retrofitted to the Bronco's frame. Fitting the '06 Dana 60 front axle proved to be a little more involved than swapping the l A 5R110 five-speed automatic transmission was already bolted up behind the 6.0L engine, so in it went. The shift linkage from the '06 Super Duty was adapted to work, and the massive 6.0L transmission cooling lines were mated to the 6.0L cooler mounted on custom brackets in front of the radiator. A 5R110 five-speed automatic transmission was already bolted up behind the 6.0L engine, so Both Broncos required a tire and wheel change to accommodate the eight-lug Super Duty axles. The 6.0L Power-Stroke-powered Bronco received a set of 315/70R17 Goodyear Wrangler AT Extreme tires, while the 7.3L Bronco rolls on a set of 37x15.50R20 Toyo Open Country M/Ts. Both Broncos required a tire and wheel change to accommodate the eight-lug Super Duty axle The extra length of the 5R110 transmission in the 6.0L Bronco meant the rear driveshaft had to be even shorter than in the 7.3L truck. It also meant that there was very little room for a muffler, which David deleted on both trucks so he could hear the turbos spool better. The extra length of the 5R110 transmission in the 6.0L Bronco meant the rear driveshaft ha The most difficult part of getting the 101/2-inch rear axle in the 6.0L Bronco was tuning the pinion angle in order to limit driveshaft vibration. The factory rear lift blocks from a Super Duty were reworked to provide the added rotation. The most difficult part of getting the 101/2-inch rear axle in the 6.0L Bronco was tuning The 6.0L swap also required that the gauge cluster from the donor truck be swapped in behind the dash (note the round '06 dials). Sharp-eyed readers will also notice that a set of Super Duty seats were also swapped into the Bronco. The 6.0L swap also required that the gauge cluster from the donor truck be swapped in behi Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!