2008 Ford F250 - Project KR, Part IV Photo Gallery
Project KR Gets a Gear Change and Lockers for the Backcountry
Chuck Eickhoff –
Nov 1, 2011
Photo 1/37 | 2008 Ford F250 Project Kr Part Four super Duty Differentials | 2008 Ford F250 - Project KR, Part IV
Photo 2/37 | 2008 Ford F250 Project Kr Part Four super Duty Differentials | 2008 Ford F250 - Project KR, Part IV
Photo 3/37 | 2008 Ford F250 Project Kr Part Four front Differential Oil Drained | 01. With the truck on a hoist, the front differential oil was drained and the cover was removed. The driveshaft was disconnected from the differential (only) and held up to the frame by a wire.
Photo 4/37 | 2008 Ford F250 Project Kr Part Four removal Of Break Caliper | 02. Ken Conklin removed the brake caliper, rotor, vacuum hoses, and brake sensors. He can now remove the hub and axle. Note that he removed them together.
Photo 5/37 | 2008 Ford F250 Project Kr Part Four checking The Factory Set Tolerance | 03. Gabriel Garcia checked the factory set tolerance with a dial indicator before removal. He did this to give him a reference for setting up the new gears and will generally duplicate the set tolerance depending on wear of gears. For this job, he is dealing with little wear and does not need to compensate for the condition of the original gears.
Photo 6/37 | 2008 Ford F250 Project Kr Part Four marking Of Bearing Caps | 04. Gabriel marks the bearing caps for side and top, which is an important step, as they have been machined from the factory to a specific side and orientation.
Photo 7/37 | 2008 Ford F250 Project Kr Part Four highlighting Of Caps | 05. The factory has identified the caps, but Gabriel highlights them even more for easy clarification during installation.
Photo 8/37 | 2008 Ford F250 Project Kr Part Four stock Ring Gear And Carrier Removed | 06. With the measurements complete and the case and caps identified, the stock ring gear and carrier were removed. Using a bar (going from side to side), Gabriel slid it out and set it on the bench.
Photo 9/37 | 2008 Ford F250 Project Kr Part Four measure Pinion Gear Nut | 07. Before removing the pinion nut, Gabriel used a torque wrench to measure pinion gear nut torque. Again, the factory specifications will be duplicated on assembly. All this checking and measuring adds time to the installation process, but this is the right way to complete the project—which is why we went with Tri-County Gear.
Photo 10/37 | 2008 Ford F250 Project Kr Part Four axlehousings Were Checked For Trueness | 08. Before the new differentials were installed, the axlehousings were checked for trueness. With the axlehousing using clear spacers to replicate the bearings, a straight round bar is slid in, going from end to end (just like the axle). If the housing is not true, there will be premature wear and possible failure of related parts in the differential.
Photo 11/37 | 2008 Ford F250 Project Kr Part Four axlehousing | 09. Looking down the center of axlehousing, the bar should be in the center. If not, a measurement can be obtained to see how far away from true you are. Our front and rear housings were both centered, showing our housings to be true. With all the checks complete, we had a green light to proceed.
Photo 12/37 | 2008 Ford F250 Project Kr Part Four wire Needs To Pass Through The Housing | 10. The ELocker requires electrical power for activation. Wire leads extend out of the locker on the locking-ring side, and they need to pass through the housing. These leads will later be connected to power via a relay, switch, and fuse panel. Gabriel located the wire position in relation to the housing and marked it with a center punch on the top of the housing.
Photo 13/37 | 2008 Ford F250 Project Kr Part Four rubber Grommet | 11. Gabriel started with a pilot drill first, followed by a final drill. A rubber grommet was supplied that was pressed in place. It seals and protects the differential and wires.
Photo 14/37 | 2008 Ford F250 Project Kr Part Four housing Interior | 12. Here is the housing interior with a new pinion gear in place and set to specifications. The ELocker is installed. A dial indicator was used again to check and confirm proper specifications compared to factory. The ring gear will be marked with white grease and checked for a good pattern between the ring and pinion gears.
Photo 15/37 | 2008 Ford F250 Project Kr Part Four elocker In Place | 13. With the ELocker in place and set, Albert can now pass wires for the locker through the top of the housing. The rubber grommet will also get silicone applied to ensure sealing.
Photo 16/37 | 2008 Ford F250 Project Kr Part Four final Inspection | 14. With the front complete, a final inspection that included checking the activation of the locking mechanism of the locker was conducted.
Photo 17/37 | 2008 Ford F250 Project Kr Part Four re Installation Of Brake System | 15. Ken Conklin slid the axles in and started the re-installation process of the braking system, vacuum hoses, and sensors.
Photo 18/37 | 2008 Ford F250 Project Kr Part Four check Threads And Mark Bolts | 16. During the reassembly process, Ken started with handtools to ensure the threads were not damaged and marked all bolts after he tightened them to ensure completeness.
Photo 19/37 | 2008 Ford F250 Project Kr Part Four re Mark The Caps | 17. Gabriel has to re-mark the caps and case on the rear housing with a punch, as the factory markings are barely visible. This will aid matching during reassembly. Remember, it’s the details that complete great work.
Photo 20/37 | 2008 Ford F250 Project Kr Part Four pinion Gear Nut Removed | 18. With the factory ring gear and carrier out, the pinion gear nut was removed. Gabriel has already taken the torque reading from the factory pinion gear, so it can be duplicated when installing the new pinion gear.
Photo 21/37 | 2008 Ford F250 Project Kr Part Four balancer Removed | 19. The balancer was removed using a puller. Extra care was taken to avoid damaging the rubber isolator within the balancer.
Photo 22/37 | 2008 Ford F250 Project Kr Part Four red Thread Lock | 20. To ensure the threads didn’t come loose when they were installed in the carrier, red thread lock was used.
Photo 23/37 | 2008 Ford F250 Project Kr Part Four tightened Ring Gear Bolts | 21. Gabriel tightened the ring gear bolts in a cross pattern, making sure the load was spread evenly to ensure a tight and even match between the surface of the gear and the carrier. Hear he is working on the ELocker.
Photo 24/37 | 2008 Ford F250 Project Kr Part Four measuring Equipment Set Up | 22. Tri-County Gear owner Jason Bunch sets up his measuring equipment that duplicates the carrier. He can then get the measurements needed for Gabriel to set up the actual locker and gears with shims and spacers prior to installing it in the housing. Jason can do this in minutes, saving Gabriel the guesswork and time it takes to slide the differential in and out.
Photo 25/37 | 2008 Ford F250 Project Kr Part Four bearings Pressed | 23. Gabriel set up the press for the Detroit Locker and pressed the bearings into place. It is critical that the bearing is started square with the carrier and is checked during the process.
Photo 26/37 | 2008 Ford F250 Project Kr Part Four shims Placed On Housing Sides | 24. Gabriel placed the right shims on each side of the housing based on Jason’s calculations. A small amount of grease was used to hold the shims in place.
Photo 27/37 | 2008 Ford F250 Project Kr Part Four white Grease Application | 25. White grease was applied to the inside of the races before they were installed on the bearings. The Detroit Locker and Superior gears were slid into the housing. The Tri-County Gear crew makes this look easy—and for them, it is.
Photo 28/37 | 2008 Ford F250 Project Kr Part Four torque Wrench | 26. With the balancer in place, a torque wrench was used on the pinion nut to reach specifications. All the previous setup time gave us the information we needed to do the job right the first time.
Photo 29/37 | 2008 Ford F250 Project Kr Part Four white Grease Applied | 27. White grease was placed in the teeth of the ring gear and then cycled to give a pattern of contact between the ring gear and the pinion gear. Grease was put on the face and the back of several teeth of the ring gear to check for depth (surface area) and backlash with the pinion gear.
Photo 30/37 | 2008 Ford F250 Project Kr Part Four mag Hytec Cover Installation | 28. With the axles and driveshaft in place, we installed the Mag-Hytec cover to give us extra cooling, more oil capacity, and more strength than the stock aluminum cover. Excessive heat is hard on the lubrication, and this cover will help extend the life of our differential.
Photo 31/37 | 2008 Ford F250 Project Kr Part Four fuse Panel Reached | 29. Mike Montana is Tri-County Gears’ electrician. While the rear was being finished, he started wiring the ELocker installed in our Dana 60. With the glovebox removed, the fuse panel was reached so a power source connection could be identified.
Photo 32/37 | 2008 Ford F250 Project Kr Part Four drill Hole In Fuse Cover | 30. Mike drilled a hole in the fuse cover and ran the wire through the cover. Then, on the underside, near the front of the dash, he ran the wire across to the driver side, where it was unseen and out of the way. The switch will be connected later, and other wires will go through the firewall.
Photo 33/37 | 2008 Ford F250 Project Kr Part Four wiring Loom | 31. The wiring loom from the differential to the cab interior was routed inside the frame for protection and goes to a relay, a switched source, and power.
Photo 34/37 | 2008 Ford F250 Project Kr Part Four relay For The Switch | 32. The relay for the switch was mounted on the inside of the fender wall. Heat can harm and affect the performance of the relay. Over time, Mike has found this to be a good spot, keeping heat and moisture to a minimum.
Photo 35/37 | 2008 Ford F250 Project Kr Part Four wires Measured | 33. Wires were measured to the right length, ensuring they would be protected from unwanted chafing.
Photo 36/37 | 2008 Ford F250 Project Kr Part Four wire Terminals | 34. Mike used wire terminals that can be heated and shrunk to the wire. They cost more, but he says they connect and seal better than regular connections, thereby minimizing failure and lasting longer. Remember...it’s the details.
Photo 37/37 | 2008 Ford F250 Project Kr Part Four elocker Switch Mounted | 35. We wanted the ELocker switch mounted in the ashtray, as we didn’t want anyone turning it on by accident. Mike is a perfectionist, so with time and modifications he made it fit right—but we’re not sure he wants to do that again.