New Rear Brakes
It turns out that getting the Bronco registered is easier said than done. It turns out that in Texas a parking brake is required to pass inspection. Therefore, a new rear disk brake setup with a parking brake was in the works.
In the state of Texas any vehicle later than 1960 must have a working parking brake to pass inspection. Specifically it states that it must be mechanical and separate from the hydraulic system. Below is the complete list of items that must pass.
2. Windshield Wipers
5. Seat Belts
6. Brakes (Parking - beginning with 1960 models)
8. Wheel Assembly
9. Exhaust System
10. Exhaust Emission System (beginning with 1968 models)
11. Beam Indicator (beginning with 1948 models)
12. Tail Lamps (2); (1) if 1959 model or earlier
13. Stop Lamps (2); (1) if 1959 model or earlier
14. License Plate Lamp (1)
15. Rear Red Reflectors (2)
16. Turn Signal Lamps (beginning with 1960 models)
17. Head Lamps (2)
18. Motor, Serial, or Vehicle Identification Number
19. 1988 and newer - inspect for window tinting or coating
20. Gas caps on vehicles 2-24 model years old.
The calipers that were on the Bronco look like front end calipers that were installed using a custom bracket to the rear Ford 9" axle. As can be seen there is no parking brake assembly nor was there a drum like parking brake assembly on the inside of the rotors. In this case the only option was a new rear brake kit. I really like having rear disk brakes, therefore, I went with a rear disc brake kit from Toms Bronco Parts.
One of the reasons I like the Tom's kit was the great video they had on YouTube. It looked like a well put together kit that was relatively simple to install. Since my Bronco already had a rear disk brake conversion it was a relatively straight forward installation. One thing to note is that you will need to specify the "size of the rear end" specifically if it is a big bearing or small bearing. This can be done by measuring the distance between bolts on the rear of the mounting flange. The big bearing measures 3.500" by 2.375" where as the small bearing measures 3.375" by 2.000". In my case I have the big bearing rear end.
Here is the finished product. One other thing I had to do was link the parking brake cable from the foot pedal to the cables that come from the rear brake assemblies. I found that doubling up on clamps creates a really strong connection between the two. Finally I bled the system and was able to pass the initial road worthiness inspection. Turns out the brake inspection includes testing the parking brake to verify that it will hold the vehicle in first gear and that the Bronco can be brought to a complete stop in about one Bronco length at 20 MPH.