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You're doing the right thing - ask lots of questions and consider the answers and how they would apply to YOUR situation.
My recommendation for your situation is a good LS in the rear (like the True Trac) and a selectable locker in the front.
The on road performance will be about the same as you have now, with none of the "negatives" of a locker on the street. And your off-road capabilities will be only marginally reduced from full lockers front and rear.
This is one of those things where if you have to ask, you better enlist help. You have to reset the ring gear, which is easier than setting up the pinion, but still not for the less experienced. Not that I judging, I will not do it myself yet.
Theoretically you can unbolt the old carrier and remove the ring gear. Then start with the same shims and check the pattern once it's together. Then adjust the shims until you get it right. However I'd be worried I'd have it in pieces and not have enough or the right shims. Or if it howled when finished I'd have to keep working on it until I decided to pay someone to do it right.
I have the ARB front and rear in my '03 F-250. Love them; they're locked or they're not. ~$1,100 installed each plus $350 for the controls and air compressor.
(So, if I start a thread about lockers and then proceed to talk about LS, does that mean I have hijacked my own thread? )
I'm concerned about a locking front diff combined with my ESOF, which has already had maintenance issues at 45k miles. Wouldn't I be well advised to swap out the vacuum hubs with manual ones?
Good questions, Mark. And you started the thread so you can re-direct it anyway you want!
On the hubs, I think it can be argued whether a locked diff or open diff is harder on a hub. The two usual hub failure (thinking breaking/exploding hubs here, not malfunctioning valves or switches) modes I've seen are:
1) Grunting up a hard obstacle, no tire spinning, just too much torque for hub to handle.
2) Shock load causing it to scatter. Like tire spinning wildly and then suddenly grabbing traction.
Mode 1 seems more common on vehicles with lockers.
Mode 2 seems more common on opens.
So I don't know if going to locker will put your auto hubs at more or less risk. When do the Ford hubs usually explode?
Personally, I don't mind manual hubs. Any vehicle with automatics get converted to a nice heavy duty, easily field servicable manual hub. And I carry a spare.
I hate to say it, but if you are doing that kind of wheeling you'll want to upgrade to an aftermarket manual hub. The factory esof hubs are too weak for serious wheeling. I love them when they work, but even I would change them out if I put a locker in the front and planned on doing something that required it. I've had these things apart and they are adequate at best for street driving.
If the concern is whether or not the lockouts will be durable enough, and you are considering an upgrade in lockouts, then you need to go a step further, and upgrade the outer stub shafts.
If your wheeling is extreme enough to warrant a locker, then the 30 spline stub shafts are not going to cut the mustard.
These small stub shafts are "weak" little things, and buying a set of decent lockouts is only going to amplify the weak link. This failure usually takes out a hub, and lockout, which requires you to buy a new one again anyway. It becomes a vicious cycle, and to prevent it,,,,35 spline shafts and lockouts should go in right away.
I will go with ARBs front and rear as they are tough enough to hold up to the abuse of sled pulling and drag racing. The factory limited slip is junk. A Detroit Locker would be my second choice. The EZ-Locker is not durable enough for the torque of a modified diesel. WARN hubs are nice but don't your vacuum operated hubs also have a manual **** you can turn if they fail? I've always been told that if you plan to stay locked for an extended length of time that you're supposed to also lock them in by hand anyway.
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