Here's why it's so complex and what's involved:
* Transmission Crossmember: You'll need a completely different crossmember to support the manual transmission. The automatic and manual transmissions have different mounting points and weight distributions.
* Driveshaft: The driveshaft length will be different, and you'll likely need a custom-made or sourced driveshaft to fit the manual transmission.
* Clutch Pedal Assembly: You'll need to install a clutch pedal assembly, including the master and slave cylinders, hydraulic lines, and linkage. This includes modifying or replacing the floorboard to accommodate the pedals.
* Clutch Cable/Hydraulics: You'll need to install the appropriate clutch cable or hydraulic line depending on the manual transmission you choose.
* Bellhousing: The bellhousing that bolts the transmission to the engine is completely different. You'll need a bellhousing compatible with both your engine and the chosen manual transmission.
* Flywheel: The flywheel for a manual transmission is different from the flexplate used with an automatic transmission.
* Shifter Linkage: You'll need to install a shifter linkage and possibly modify the transmission tunnel to accommodate it.
* Wiring Harness: The automatic transmission uses various sensors and solenoids that a manual transmission doesn't. You'll need to modify or replace the wiring harness accordingly. This might involve removing the computer controls for the automatic transmission.
* ECU/PCM: Your Engine Control Unit (ECU) or Powertrain Control Module (PCM) is programmed for an automatic transmission. You might need to reprogram it or potentially use an ECU from a manual transmission Bronco, though compatibility is not guaranteed.
* Finding the Right Manual Transmission: Not all manual transmissions will be compatible with your 1994 Ford Bronco's engine and drivetrain. You need to find one that's the correct type and gear ratio. ZF-5, T-18, and possibly others from suitable years are possibilities, but confirming exact compatibility is critical.
In short: This is not a weekend project. You're essentially rebuilding a significant portion of your vehicle's drivetrain. It requires specialized tools, deep mechanical knowledge, access to parts (many of which will likely be used or require modification), and potentially custom fabrication.
Recommendation: Unless you have extensive experience with automotive transmission swaps and fabrication, it's strongly advised to take your Bronco to a professional mechanic specializing in this type of work. The cost of a professional conversion will likely be substantial, but it's significantly less than the cost of making mistakes during a DIY conversion, potentially damaging your vehicle in the process.
