Ford F-150 Suspension Modifications - Thunder From Down Under

The kit-supplied forward upper control arm brackets attach to the OEM shock mount brackets. The upper arms then span between this point and the upper portion of the lower axle bridge.

Large brackets are bolted to the left and right framerails, using some existing holes as locator points, and additional drilled holes. These brackets act as upper mounting points for both the air springs and the kit's dampers, as you'll see in upcoming photos. The left one also acts as the chassis-mount point for the upcoming Panhard bar.

One more important bracket attaches to the right upper corner of the differential pot, again using factory fastener holes. This is the axle mount point for the Panhard bar.

The Panhard bar connects chassis and axle, thereby providing precise lateral control of the axle, while still allowing full vertical movement of the housing.

Pretty much all that's left for the AirBAR setup is bolting the air springs and double-adjustable dampers in place.

The LevelPRO ride-height sensors are installed to measure the relationship between a moving chassis component-the upper control arm, in the case of the rear setup-and the chassis. As the suspension moves up and down, the lever arm on the sensor follows and tells the system ECU the relative position of each of the vehicle's corners.

Here's a side shot of the completed AirBAR installation, showing the orientation of the various components. Normally, one would now proceed onto the air system and wiring, but because Thundertruck is also getting Air Ride's cool LevelPRO system, there are some height sensors to be fitted at each corner of the vehicle.

Up front, Air Ride's Rodney Mason sets up the height sensors to span between the framerails and aluminum lower control arms. It's obviously imperative that the sensor hardware be fitted so as not to interfere with movement of any suspension components.

The system's 5-gallon air tank and pair of compressors were mounted to the outside of the framerail, roughly beneath the passenger door. The air-valve assembly (not visible here) was bolted up inboard of the framerail.