Aonarch’s 2023 Bronco Build

[Aonarch]

I finally bought a Bronco after giving up on my Badsquatch order after several delays.

2023 Outer Banks Luxury Package with the 2.7l. Purchased for MSRP off the lot.

Immediate Plans:
Eaton TrueTrac LSD in the rear keeping 3.73 ratio. I am leaning more towards this option versus going with the M210 FDU, since my normal off-roading are rough gravel roads and I never plan on going larger than a 34" tire.

Ford Performance/ Bilstein 6100 2” lift

OEM Rock Rails with steps.

Wheels and tires: planning on running either a 255/75/17 in a Destination AT2 (My favorite light AT tire) a 255/80/17, or 285/75/17 probably in a Wildpeak ATW3.

I have been into off-roading for 20 years now, but now more into Overlanding. Here are a few of my past rigs, minus a 2nd gen Tacoma:

Here is my on-going mod/ wish list:
INSTALLED https://www.levittownfordparts.com/sku/m-18000-b1a.html
2" Ford Performance Lift Bilstein 6100s

INSTALLED https://www.rtrvehicles.com/collections/bronco-rtr-parts/products/bronco-rtr-evo-6
RTR Evo 6 wheels in 17x9+30 Satin Charcoal

INSTALLED https://www.firestonetire.com/tire/destination-at2/P285-70R17/
Firestone Destination AT2 in 285/70/17 (Keeping tires tame for now)

INSTALLED https://www.amazon.com/dp/B09BK52N6W?psc=1&ref=ppx_yo2ov_dt_b_product_details
CravenSpeed Stubby Antenna

INSTALLED https://www.levittownfordparts.com/sku/vm2dz-78519a02-a.html
Genuine Ford Windshield Sunscreen By Covercraft

INSTALLED https://www.fastintentions.com/product/f-i-bronco-6g-sill-guards/
Fast Intentions door sill guards

INSTALLED https://www.bartact.com/products/br...co-full-size-2021-2022-2023-pair-of-2-bartact
Bartact paracord grab handles

INSTALLED https://www.amazon.com/gp/product/B07H56TP4F/ref=ppx_od_dt_b_asin_title_s00?ie=UTF8&psc=1
Ronin Factory Oil Drain Plug (Will change engine oil at 1,000 miles with a full synthetic)

INSTALLED https://www.ruxerparts.com/oem-parts/ford-plate-mb3z7e063a?c=bD00Jm49Q2F0ZWdvcnkgUGFnZQ==
Transfer case skid plate

INSTALLED https://www.levittownfordparts.com/sku/m2dz-78102d30-aa.html
2 door rock rails

INSTALLED
OEM Rear Sway Bar

INSTALLED https://www.rockjock4x4.com/RJ-286100-101
Rockjock Antirock front sway bar

INSTALLED https://www.rockjock4x4.com/RJ-181400-101
Rockjock Track Bar Bracket

INSTALLED https://www.amazon.com/IAG-Performance-EZ-Step-Bronco-Below/dp/B0B7L6384Q?ref_=ast_sto_dp
IAG V2 EZ-Step Add-on for 2021+ Ford Bronco Black 2 Door

ORDERED https://www.levittownfordparts.com/sku/m-1613208-b.html
Ford Performance sill plates

INSTALLED https://www.levittownfordparts.com/sku/m-16826-b.html
Ford Performance hood struts

INSTALLED https://accessories.ford.com/bronco-2021-2023-bronco-silver-script-emblem-kit
OEM Bronco fender emblems from the Heritage trim

INSTALLED https://www.jcroffroad.com/product/BR6-TAB.html
JCR rear hatch table

INSTALLED
Yamika K Platform with Timberline Towers

INSTALLED https://badasstents.com/product/2021-23-ford-bronco-wind-deflector-for-oem-roof-rack/
Badasstents Wind Deflector for OEM Roof Rack

INSTALLED
IAG Mini Front Mud Flaps

INSTALLED
IAG Rear Mud Flaps

INSTALLED https://www.rockworkx.com/products/...-fastener-thumb-screws?variant=41980730441924
Rockworkx Quick Release Hardtop Bolts with D Rings

https://www.levittownfordparts.com/sku/mb3z-10317-j.html
TSB alternator cover (Not sure if I need this, I'll have to check my part number)

https://www.levittownfordparts.com/sku/he5z-78115a00-a.html
cargo organizer

https://www.stage3motorsports.com/9...-truetrac-limited-slip-differential-rear.html
https://www.levittownfordparts.com/sku/m-4210-r.html
https://www.drivetrainspecialists.com/dana/dana-m220/dana-m220-373-ratio-ring-and-pinion-set.html
Eaton Truetrac LSD with new 3.73 R&P and install kit

https://www.levittownfordparts.com/sku/m-9603-b27.html
Ford Performance Tune

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[rguest3]

Another great looking 2-Door!

18" Wheel / Tire now, correct? Do you like your current 18" wheels? 285/75/18 Toyo ATIIIs (little taller than Sasquatch) with the 2" lift listed would look great!

I would go with 4.70 gears / Axles as well, depending on what size tire you choose.

The factory running boards and most other steps, to me, are too high. Once you step up you then have to duck your head to get inside the truck. I would go with AMP or RockSlider for the side steps. They are up and out of the way when driving and a lower deployed step for easy access when you get in and out.

Here is a picture of the 285/75/18s with a Sasquatch Suspension and a 1" Level Lift. this would be similar to the 2" lift.

 

[Ford Motor Company]

I finally bought a Bronco after having cancelled my OG Badsquatch order after several delays.

2023 Outer Banks Luxury Package with the 2.7l.

Immediate Plans:
Ford Performance M210 front differential 4.7 with locker, CVs, and Ford Performance tune
Rear 4.7s with Eaton elocker

Or

Eaton TrueTrac LSD in the rear keeping 3.73 ratio. I am leaning more towards this option, since my normal off-roading are rough gravel roads.

Ford Performance/ Bilstein 6112 2” lift

OEM Rock Rails with Hoop Step? Is that a thing. I need to ditch these running boards ASAP.

Wheels and tires: planning on running either a 255/75/17 in a Destination AT2 (My favorite light AT tire) or a 255/80/17 in a Toyo AT3. There is a small possibility that I run BFG 34x10.5s.

Congrats! Here's to many great adventures with your new Bronco!

 

[indio22]

I finally bought a Bronco after having cancelled my OG Badsquatch order after several delays.

2023 Outer Banks Luxury Package with the 2.7l.

Immediate Plans:
Ford Performance M210 front differential 4.7 with locker, CVs, and Ford Performance tune
Rear 4.7s with Eaton elocker

Or

Eaton TrueTrac LSD in the rear keeping 3.73 ratio. I am leaning more towards this option, since my normal off-roading are rough gravel roads.

Ford Performance/ Bilstein 6112 2” lift

OEM Rock Rails with Hoop Step? Is that a thing. I need to ditch these running boards ASAP.

Wheels and tires: planning on running either a 255/75/17 in a Destination AT2 (My favorite light AT tire) or a 255/80/17 in a Toyo AT3. There is a small possibility that I run BFG 34x10.5s.

Nice Bronco. But given "my normal off-roading are rough gravel roads", then you don't have a use for a front locker and likely not a rear either.

 

[Aonarch]

Another great looking 2-Door!

18" Wheel / Tire now, correct? Do you like your current 18" wheels? 285/75/18 Toyo ATIIIs (little taller than Sasquatch) with the 2" lift listed would look great!

I would go with 4.70 gears / Axles as well, depending on what size tire you choose.

The factory running boards and most other steps, to me, are too high. Once you step up you then have to duck your head to get inside the truck. I would go with AMP or RockSlider for the side steps. They are up and out of the way when driving and a lower deployed step for easy access when you get in and out.

Here is a picture of the 285/75/18s with a Sasquatch Suspension and a 1" Level Lift. this would be similar to the 2" lift.

I love Bilstein 6112 coilovers and had them on my GX 460. The Ford Performance lift uses custom valved Bilstein 6100s so for me that is a match made in heaven.

Your rig looks awesome. I do love that tire size! I'm not a fan of wide tires, I prefer pizza cutters.

 

[Aonarch]

Nice Bronco. But given "my normal off-roading are rough gravel roads", then you don't have a use for a front locker and likely not a rear either.

100% that is why I think I will just go with the LSD.

EDIT: I also do not see myself going larger than a skinny 34, so I think 3.73s will be ok.

 

[Aonarch]

Ordered the Ford Performance Lift Kit. As I stated I am a huge fan of Bilstein 6000 series, which this kit uses with custom valving.

 

[Aonarch]

Did all of the forscan changes like stop start, chimes and I added Baja mode.

Ordered a transfer case skid, that is the only skid plate that I am missing. I read through threads of people having a steel front, plastic engine, or plastic gas. Who knows... My front skid, engine skid and fuel tank skid are all steel from the factory. The Ford B&P tool says the OBX does not have steel skid plates.... But then people say all two doors get a steel fuel skid. Confusing.

RANGER SKID DOES NOT FIT. Ordered the correct Bronco skid thanks to flip.

Removed the steps.

 

[Aonarch]

Pretty easy job. Front driver took some stomping to get the old coil over out and the new one in. Passenger side was a breeze. I did end up taking off the front calipers to reduce the strain on the brake lines and help reduce the weight that I had to manipulate with the spindle.

The rear is super simple except for the stupid fender liner. Those plastic screw push pins are awful. Half of them had to get forced out. I ended up replacing them with Amazon 6.3mm clips.

The FP Bilstein kit is super nice, has Sasquatch springs and top hats out of the box set for two inches of lift. Not having to mess with four top hats is a huge time saver. No instructions in the box, but every nut and bolt was included, which is nice, even the axle nuts and the rear lower shock bolts. I didn't have any issues getting the rear shock bolt out. I used a 27mm deep socket on my 400lbs impact and a 30mm deep socket on a breaker bar and just sent it.

In case anyone needs torque specs:
Suspension Torque Specs
Upper front strut nuts 41 ft lbs 15mm
Lower front strut nuts 66 ft lbs 18mm socket
Tie rod 46 ft lbs 21mm
Sway bar links 32 ft lbs 21mm
Upper ball joint 46 ft lbs 18mm
Axle nut 35mm 221 ft lbs
Rear strut upper nuts 41 ft lbs 15mm
Rear strut lower bolt 350 ft lbs 30mm/ 27mm deep impacts
Wheel nuts 100 ft lbs 19mm

I didn't torque the strut tops, just good n' tight. I also didn't put a torque wrench on the rear coilover bolt, just good n' tight with my big ass impact. I re-checked the nuts and bolts about 100 miles later.

 

[Aonarch]

Still haven't decided on wheels, but I am leaning towards some EvoCorse in 17x8 +30 offset if I want to be bougie.

 

[Aonarch]

Here is my math on Sasquatch vs Non-Sas. I had an Eruption Green 2dr Badsquatch on order for over a year and a half, but cancelled after many delays.

Sasquatch wheels are 36 lbs and the Territory MTs are terrible tires. If I bought a Sasquatch, I'd personally sell the factory wheels and tires ASAP. I also prefer skinnier tires, so I'd want to run 285/75/17. I'd sell the factory SAS suspension and upgrade to the Ford Performance lift kit at a minimum.

The major benefit to the Sasquatch package FOR ME is the M210 front drive unit and the factory lockers, but I prefer the Antirock vs the factory disconnecting sway bar.

Sasquatch from the factory is an amazing package. Going aftermarket or retrofit OEM is a hassle and can introduce some further hassle with warranties. Don’t take this as Sasquatch bad, I wanted one and had one on order.

Note this math is guestimations with my local sales tax and some rounding up and down.

 

[Aonarch]

Post lift.

Still deciding on wheels and tires. There is a set of brand spanking new Badlands beadlocks for sale at my local dealer, but they have 33” KO2s on them. The price is right though. I want to run 285/75/17.
I also put back on the running boards since my SO is 5’2’ and my sliders haven’t shipped yet.

 

[MNBigfoot]

I wrote this in another thread, but here is why I am happy that I cancelled my Sasquatch order and bought a non-SAS Bronco off the lot, not taking into account the never ending wait.

Sasquatch wheels are 36 lbs and the Territory MTs are terrible tires. If I bought a Sasquatch, I'd personally sell the factory wheels and tires ASAP. I also prefer skinnier tires, so I'd want to run 285/75/17 or 35x11.5s anyways.

The major benefit to the Sasquatch package FOR ME is the M210 front drive unit and the factory lockers. I prefer the Antirock to the disconnecting sway bar, and I would go Antirock either way.

Here is where the mental gymnastics happen; you can add the FDU for about $3000, but that also includes the Ford Performance tune ($700), which I'd do anyways with a SAS. All Broncos have the M220 rear end, you'd just need to re-gear to match the front drive unit gearing if you have a rear locker. If you do not have a rear locker you can either do a LSD, a elocker, or an air locker. That runs about $1700-2000 with labor. NOW... None of that is from the factory as built and includes so added risk or uncertainty. I will say the Ford Performance parts usually include a 3/36k warranty, so that certainly helps.

Here is my personal math buying a Sasquatch vs. not:
- Sasquatch is $5k option
- Sell SAS Suspension $1k
- Ford Performance lift $1800 + $100 for alignment
$5900 in the negative
- Sell SAS wheels and tires $2400? Wheels alone can be sold locally for $1200-1500
- Aftermarket wheels and tires are lets say $3000 for 5
$6500 in the negative if not more
- Antirock front sway bar $900 (I don't like the factory disconnect it adds weight and complexity)
I don't think anyone would buy the factory disconnect, so $0?
Including SAS package, we are now at $7400 in the hole.

Now let's add in adding the FDU, rear locker and rear gearing:
- FDU $1700
- Front CVS $440
- Ford Performance tune $670 (I am not including this, because I'd do this even if I had a Sasquatch)
- Rear gears, install kit and locker $1200 plus labor since pretty much no one does their own gears $1700
That is $3840 to upgrade the front and rear axles to Sasquatch spec, not cheap and again not as built from the factory.

That is $3,560 wasted FOR ME, for my specific use case. If you can't DIY throw in labor costs.
Obviously the main issue is, Sasquatch is a complete package right from the factory, full warranty, engineered to work... while this method requires a lot of labor, logistics, and uncertainty. YRMV.

Don't take this as, "Sasquatch is bad." No, the SAS package is amazing and I had one on order. But since I couldn't get one due to delays and other drama, I am happy that my math shows a bright side to this.

I guess I'm not following your math........ Why didn't you add in the Ford Performance lift ($1900), wheels and tires ($3000), and antirock ($900) in your alternative to Sas package? That would bring your total for the alternative plan to $9640 minus the sale of your OB tires ($500?)..... So bringing the two plans to the equal goal, would cost you an extra $1700 not $3560 in savings.

 

[Aonarch]

I guess I'm not following your math........ Why didn't you add in the Ford Performance lift ($1900), wheels and tires ($3000), and antirock ($900) in your alternative to Sas package? That would bring your total for the alternative plan to $9640 minus the sale of your OB tires ($500?)..... So bringing the two plans to the equal goal, would cost you an extra $1700 not $3560 in savings.

My math might be a little screwy, but my point was, if I bought Sas, I would have upgraded everything anyways, minus front and rear axles.

EDIT: I just redid the math in excel and found it all to be a wash.

 

[MNBigfoot]

My math might be a little screwy, but my point was, if I bought Sas, I would have upgraded everything anyways, minus front and rear axles.

EDIT: I just redid the math in excel and found it all to be a wash.

Just to make sure I got this right; you regeared to 4.7, got an extra .9" of lift over Sas, and have a LSD, but still no front locker?

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