Forge Specialties, Super Duty Air Lockers & Dual Compressor

35inchoverdrive

Adventurist
We've got an '08 F250 at the shop:

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It's a 4x4, 6spd manual, turbo diesel with manual door locks, window cranks and vinyl bench seat:
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...and pretty much every Dana 60 and Sterling 10.5 need these.
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...cracking into the axles.
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The rear Sterling axle sports 3.73 gears and a factory limited slip(which is doing more slipping than limiting).
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The ARB case spreader comes in handy to take the preload off, so that the case can be removed.
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...checking the backlash. There's a fair amount of in and out in order to get the right combination of shims and the ridiculously huge carrier doesn't seem to get any lighter, toting it back and forth between the bench.
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...installed.
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On this particular axle, you have the option to drill the bulkhead fitting on the LHS of the diff, so that the copper line doesn't have to cross the ring gear.
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The rear is all buttoned up.
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The front Dana 60 is a bit more time consuming.
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...tearing down the brakes and popping out the shafts.
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The stock front diff cover was super crusty, so it was a great time to step up to a Solid diff cover.

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It's a big strength upgrade over the stamped steel cover.
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...no one likes open differentials...
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We love our Cuisinart ring gear heater. It makes sliding the ring gear over the new carrier a breeze.
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Locking Differentials...they're like mechanical justice...
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...and this would be justice...clad in BEEF.
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We've got to take a minor detour into Generalserviceland to deal with some crusty U-joints.
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They REALLY didn't want to come out, so we asked our friend Bailiegh to help.
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Although they had been greased, the cap on the left hadn't seen any lubrication for quite a while.
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With new U-joints installed in both axle shafts, is was time to press on the ridiculous wheel seals.
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I'm not sure they are quite big enough.
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Like many modern vehicles, there is very little underhood space and there is NO WAY that ARB's monster dual compressor is going to fit under there.

In this instance, we chose to tuck it up under the bedside.
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...fabbing up a compressor mounting bracket, 1 part steel, 1 part sharpie.
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Drill baby, drill.

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Break out the dimple dies, so you know you're fabbing.

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After a little press-break action, the bracket is starting to take shape.

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The frame side of the bracket gets added, with some hardware tacked in place. This bracket bolts up to existing holes in the frame. We don't like to add holes to a rig if we don't have to.
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Here's a shot of the bracket, bolted to the frame.
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The compressor tucks up there nicely.

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...adding some paint.

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...installed. Stay turned for non-stop air plumbing and wiring thrills.
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Sexy. Wish ARB made parts for my rig...

That's a nice looking compressor mount!!

Thanks!

With regard to air plumbing, we've found a rear bumper mounted air chuck to be super handy on pickups. You can still reach anywhere on your own truck with a single, conventional air hose, and you can also reach just about anywhere on a trailer that your towing. The same thing goes for reaching other people's rigs.

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...the backside.

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...magic blue line exiting the front diff.

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The front air line and rear air line come together just above the rear axle.

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Both lines are plumbed into the manifold and solenoids on the rear crossmember.

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Since this model is bare bones, there's a very ergonomic, blank panel just to the right of the steering column.

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Why does it take so long to install air lockers? ...because even after you pull both axles completely apart and get all the mechanicals back together, you have to run wiring everywhere.

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The compressor will actuate off of one of the factory upfitter switches. The lockers are wired to be electrically dependent on the compressor being on, so that you can't accidentally turn on the front locker(with residual air in the lines) while running down the road at speed.

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...putting together some Deutsch connectors, wiring and heatshrink to make the locker and compressor controls. This will pass through the cab corner, via a cord-grip. A couple of extra dead wires will make wiring future accessories much easier.

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...installed.

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Everything appears stock with the trim tucked back into place.

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