08 FX4 SAS

[Mr. Bossley]

Well I'm back. Been super busy with work so I haven't had a lot of time for the truck.

But I got the clutch issue fixed. Ended up being a failing master cylinder not allowing fluid to return, which was maintaining pressure on the slave and causing the clutch to slip. Of course I didn't find that out till I pulled the trans out. So I just changed the master, slave, throw out bearing and pilot bearing while I was in there. Clutch and flywheel looked perfect so I just reinstalled those.

Now the truck is up on jack stands. I decided to get new tires while the truck is down. It takes like 2 months to get these tires so might as well wait while the truck is broken anyways. Exact same tires just a fresh set. Hopefully I'll have them in June.

And the steering stuff has arrived! Nice big shipment from PSC. Pump, ram, reservoir, cooler and some other accessories. So next I'll be figuring out how to fit all that up.

 

[Uncle Gump]

That's a pretty pricey looking pile-o-parts Mr. Bossley... Rock On man

 

[Mr. Bossley]

First off I got myself a welder finally. I got tired of using a friends all the time. Liking it so far. I don't know why I didn't get one sooner. And I'm glad I got the bigger 210A. This thing rips!

Now an update on the hydro assist project.

I started off by trying to make the new pump work in the stock bracket. It bolted in but there wasn't enough room for the massive -12 feed. I tried notching the stock bracket but it was still a bit tight. I could have cut out more but I decided to just build a new bracket from scratch and delete the A/C. This frees up so much space for the new reservoir and also allows me to rotate the pump so the feed comes in the side. I don't like how Ford mounts the pump fed from the bottom. I think this setup is going to work much better.

Then I went on to mounting the ram and cooler. I used some of the old condenser brackets to mount the cooler. And just welded on the PSC brackets for the ram along with the Trail Gear tube clamp.

Next I have to figure out how to mount the reservoir just right for good flow into the pump. I'll have to make a bracket for that as well.

Then it will be on to drilling/tapping the steering box, making all the hoses and getting a new belt. Coming along nicely.

 

[Mr. Bossley]

Pump and Reservoir are all mounted. And I picked up the new belt today. Getting there.

 

[Mr. Bossley]

Got the box drilled and tapped for the ram yesterday. Reinstalled it, connected all the lines & started to bleed the system. But I ran out of fluid before I could finish. It took a full 2 litres and I haven't even started the truck yet! So I'll be getting more today and hopefully have this thing driving again.

 

[dvdswan]

Great looking truck and pictures. Hopefully they will open the border soon if they haven't yet. Still need to do some exploring in BC. Bucket list item.

 

[Mr. Bossley]

Great looking truck and pictures. Hopefully they will open the border soon if they haven't yet. Still need to do some exploring in BC. Bucket list item.

Thank a lot! I've actually wanted to go check out some trails in WA lol. Some videos I've seen look decent.

 

[Mr. Bossley]

Well it's done. Got it all wrapped up today. I haven't even taken it for a test drive yet but I messed around in the driveway a bit and it seems to work.

What a project. It all went pretty smooth but still was a ton of work. Can't wait to test it out. Hopefully next weekend.

 

[alex25s16]

First off I got myself a welder finally. I got tired of using a friends all the time. Liking it so far. I don't know why I didn't get one sooner. And I'm glad I got the bigger 210A. This thing rips!

Now an update on the hydro assist project.

I started off by trying to make the new pump work in the stock bracket. It bolted in but there wasn't enough room for the massive -12 feed. I tried notching the stock bracket but it was still a bit tight. I could have cut out more but I decided to just build a new bracket from scratch and delete the A/C. This frees up so much space for the new reservoir and also allows me to rotate the pump so the feed comes in the side. I don't like how Ford mounts the pump fed from the bottom. I think this setup is going to work much better.

Then I went on to mounting the ram and cooler. I used some of the old condenser brackets to mount the cooler. And just welded on the PSC brackets for the ram along with the Trail Gear tube clamp.

Next I have to figure out how to mount the reservoir just right for good flow into the pump. I'll have to make a bracket for that as well.

Then it will be on to drilling/tapping the steering box, making all the hoses and getting a new belt. Coming along nicely.

Just wondering what welder you got?

 

[Mr. Bossley]

Just wondering what welder you got?

It's a Hobart Handler 210 MVP

 

[Mr. Bossley]

So the steering and clutch have been working awesome but more parts are piling up. Must be time for a rear diff swap lol

I was hearing a some squeaking coming from the rear end so I checked the drum brakes and found a broken tensioner cable and a bent shoe. Something must have bound up in there. But instead of rebuilding the drums I figured I might as well put the explorer diff in finally. And while I'm at it put in some 5.5" Chevy leaf springs. Hopefully they give me the ride height I'm going for with no lift blocks.

Getting started on it this weekend. Should be fun.

 

[Mr. Bossley]

Here's my progress. I got the springs and hangers removed. Removing those frame rivets was kind of a pain but I got them with a combination of grinding, drilling and air-hammering. Did it all without removing the box so that's nice.

Then I decided I want to do my sliders while I'm in here. I've been tripping over them in my shop so they need to go. And I also decided to make it a bit more difficult on myself by making them bolt-on/removable. So I've spend the last few shop sessions fabbing the mounts and cleaning the frame for paint.

I have the sliders hanging by the middle mount for now. Still need to finish the front and rear mounts then gusset everything. After that I'll resume the spring/diff swap lol.

But this morning I'm leaving for a week long vacation on Vancouver Island.

 

[Mr. Bossley]

Well I'm back from the island. Did the full tour from top to bottom. What a beautiful place. Now its back to work..

I got the gas tank removed so I can drill the holes on the driver side. Those fuel line connectors were kicking my ass for a while but I managed to get them off without breaking. Cleaned probably a few pounds of dirt from inside the frame and crossmembers. I found some reducer spacers for the spring hangers and got them welded in. These shrink the hole size to 9/16" to match the chevy leafs. Stock ranger hole was 5/8". Then got both spring hangers mounted. Now I need to finish the last mounts for the sliders, weld some nuts inside the frame where the tank sits, paint the frame, then throw the tank and new springs in.

I decided I'm going to get the truck back on the road with the stock diff for now. Just test out the new leafs, see how everything sits, and do some wheeling. My buddy and I are itching to go out so I'll build the new diff as much as I can while the truck is usable. Then it should be a fairly quick swap once it's ready.

 

[Bird76Mojo]

Why did you move the front leaf spring hangers forward? The Chebby leafs longer?

Also. where did you find those reducer bushings? I really could have used those on my 2001 when I swapped in the FR34 leafs.

Are they these 5/8" to 9/16" - https://www.ballisticfabrication.com/products/reducer-spacer?variant=32409791332427

 

[Mr. Bossley]

Why did you move the front leaf spring hangers forward? The Chebby leafs longer?

Also. where did you find those reducer bushings? I really could have used those on my 2001 when I swapped in the FR34 leafs.

Are they these 5/8" to 9/16" - https://www.ballisticfabrication.com/products/reducer-spacer?variant=32409791332427

Yes the Chevy leafs are about 6" longer. This should position the axle close to stock and keep the shackle angle right. In theory.

I got mine from barnes 4wd. Called repair washers. They are 3/4" to 9/16"

Repair Weld Washer 9/16"

Repair Weld Washers are intended to repair, and reinforce damaged or deformed mounting holes in bracketry. Drill out the damaged hole to fit the selected weld washer, insert, and weld in place. Manufactured from 1018 steel, ships bare, and ready to weld. Mig, tig, and stick weld compatible...

www.barnes4wd.com