In in my experience the stock 05-07 bolts are not long enough and only engaged half of the threads in the steering box. I used longer flange head bolts and would encourage you to make sure the stock bolts fully engage the steering box.

 

After installing my 05-07 box I did notice as well they don’t seem to be long enough. Do you recall what size and thread pitch they are?

 

Just as an update, I installed a home-made version of the Baja Customs Tracinator track bar. Trac-inator

Matt (msuser) contacted me about building them, and I agreed to build/install one if he sourced the parts. My hats off to him for doing all the leg work and research to build the bars. He is awesome to say the least, and his thread regarding his complete rebuild of his Excursion (that led to him doing the track bar upgrade) from the ground up is worth a look. Very educational in its own right.

I cannot say enough about the difference this bar makes over the stock bar with the (lousy) ball joint. 90% of the road feedback to the steering wheel is eliminated. We were able to build these for about $300 (with powder coating the bar). Maybe Matt can post the parts he ordered in his build thread when he gets time...

As a little background to the install, my MevoTech tie rods completely wore out after 40K miles. I replaced those with Moog ends, and things got back to better...but not what it was right after initial install of these axles. The ball joint on the axle for the stock track bar wore out shortly after the tie rods at 42K, and I got to experience the death wobble mentioned earlier in this thread when that happened. It was a white knuckle, terrifying experience. If I never do that again, it will be too soon. I replaced that Moog Heavy Duty ball joint with a Motorcraft the next day. It was much better, but I could still feel the road feed back in the steering wheel in the bigger bumps. I just didn't trust it any more after the death wobble experience. Ironically, Matt called me a week later and asked me if I was in to build our own track bars. Boy was I ever. Talk about good timing, as I about to send Baja Customs a bunch of my money...

I have had no problems with the 05-07 bolts that I used to attach the 07 steering box. Still tight and holding fine. I don't recall noticing a problem with length...just diameter. I think there might be a problem on length with the 08-10 bolts, though.

 

I used a 14x1x140mm 10.9 bolt and it was about perfect for me.

 

When I started bringing in parts for my build, I got a bit out in front. I ordered a complete SSTL brake line kits from SS Tubes.....for a leaf spring truck. I hadn't planned on the coil spring swap, softer those arrived....I changed my mind on the coil spring front.

My question is...what did you do with the extra length of brake hard line? As you know, the leaf spring trucks the hard line to flexible line connects behind the shock mount. On the coil spring truck, it connects in front of the coil bucket....which leaves some extra hard line. I was thinking of cutting it off and reflare...but the word on the street is double flaring 3/16" SSTL is difficult.

 

I bent the existing line back around...gently...to the front of the coil bucket and just connected it there. You can see it in the top picture...

 

Thanks Mike for the kind words. Just trying to repay all the kindness and knowledge I've received here. Sorry it took me a while to compile this list.

Here are the part numbers at Summit Racing
https://www.summitracing.com/parts/FKB-FKSSX16T-F1 Spherical bearing. This is held in a custom made cup by an internal snap ring, and the cup held into the axle with an external snap ring.
https://www.summitracing.com/parts/FKB-JMX16T-F1 Heim. This has a custom made bushing in the bearing and held into the frame bracket with the existing bolt.
https://www.summitracing.com/parts/fkb-16-12hb Misalignment bushing. These are too long and need to be machined down.
https://www.summitracing.com/parts/fkb-sjnr16 Jam nut for Heim
https://www.summitracing.com/parts/sit-ws10006pk Heim seals

This is from McMaster-Carr
90201A657
90850A400
93591A700
98410A520



The rest of the parts (bar, yoke, spacers for Heim) were all made/machined at a local machine shop.


I don't know for sure what size the internal snap ring is, but I have mine and I'll measure it.
The first 4 items at Summit are made by FK Rod Ends ? Precision Rod Ends and Spherical Bearings. If you take off the first 3 letters of the Summit part number (FKB), and the F1 at the end of both bearings, that is the FK Rod Ends part number. F1=Fit 1 which is the tightest bearing, followed by F2 (the default if you don't specify) and F3 (the loosest).

My steering gear bolts were also too short.

Now I need to get busy and updte my build thread.

 

"Flattery is when they copy your idea. Respect is when they give you the credit..."

 

Is the reason we are using the donor cables due to the attachment method on the lever at the rear axle? The levers from the 04 and older f250/excursion are the same as the new except for the attachment method for the cable. If we switch the levers, can we use our existing cables?

 

Pics for reference...

Excursion/older style

Newer style

 

I wish that I would have changed the levers. (retaining the original p/n for the brake cables) However, I didn't, and have a bunch of money in new cables...and have to figure out the new mounting point for the cables....changing the levers would have solved a BUNCH of trouble.

 

Well I had the cables from the donor but had them behind my business drying after cleaning them really good and I'm guessing a scraper came and scooped them up. Who else would take them. They were only out there for 30 minutes. So I started looking at the assemblies and realized(I think] the only difference is the lever attachment method.

 

I agree...IF you can just change the levers it saves a lot of hassle switching out the cables and finding new mounting points to support the newer cables so they will pull the shoes tight without flexing too much.

Original idea to use the cables from donor was due to different attachment method on brake shield.

 

I know you reused the 07 brake lines but do you know if you could reuse the front flex lines from a leaf sprung truck? My newer lines were trashed and my flex lines on my truck currently are fairly new, I’d hate to have to buy new again

 

The mount for the leaf spring hoses gets covered by the spring bucket. I suppose you could look at fabricating up a mount to retain the old style hoses.