Section 8: Exterior Systems¶
Recovery equipment and air systems for offroad capability.
Contents¶
| Section | Component | Description |
|---|---|---|
| 8.1 | Warn Zeon 10-S Winch | 10,000 lb winch, 409A peak |
| 8.2 | ARB Twin Compressor | Brushless 90A compressor, 1-gallon tank, auto pressure control |
| 8.3 | ARB Air Lockers | RD166 front (Dana 60), RD140 rear (Sterling 10.5) |
| 8.4 | Rear Air Chuck | External air access in tailgate area |
System Overview¶
Recovery:
- Warn Zeon 10-S winch (10,000 lb capacity, 409A peak)
- Direct AUX battery connection (1/0 AWG, no external breaker)
- Dash rocker switch + factory wired remote
Air System:
- ARB Twin Compressor (brushless, 90A draw)
- 1-gallon air tank (135-150 PSI automatic pressure)
- ARB front/rear air lockers (RD166 front, RD140 rear)
- Rear air chuck plate for tire inflation
Power Distribution¶
| Component | Power Source | Protection | Control |
|---|---|---|---|
| Winch Motor | AUX battery direct | None (internal) | Dash rocker/remote |
| Winch Control | BODY PDU CB43 | 10A | Dash rocker |
| Compressor | SafetyHub MIDI-1/MIDI-2 | 2× 60A MIDI | SwitchPros OUT-11 |
| Front Locker | SwitchPros OUTPUT-17 | Low-side driver | Button 9 |
| Rear Locker | SwitchPros OUTPUT-10 | 15A | Button 10 |
Outstanding Items¶
High (1)
- ARB RD140 fitment with Revolution F10.25-513L in the Sterling 10.5 housing (#300) — The rear runs a 10.25" ring gear (Revolution F10.25-513L) in the 10.5 housing with the ARB RD140 carrier (Ford 10.25/10.5, 35 spline, all ratios). Confirm with ARB or Revolution that the RD140 flange and ring gear bolt pattern match the F10.25 gear in this housing before ordering, and confirm the pinion depth starting point (owner note: add roughly 0.120" to the pinion depth stack).
📋 Medium (3)
- Air locker air line service loop length at full droop (front and rear) (#303) — Measure the ARB air line service loop needed at each axle at full droop on the ORI struts (14" front, 16" rear travel), not at ride height. Sets the air line kit segment lengths from the manifold under the passenger seat (baseline estimates ~12 ft front, ~6 ft rear).
- Front Air Locker Solenoid Routing (#81) — Path for 18 AWG (~12 ft) from SwitchPros OUTPUT-17 (passenger rear wheel well) to front axle solenoid - cross-cab + forward
- Winch Trigger Control Routing (#80) — Path for 14 AWG control wire (~13 ft) from SafetyHub ATC-1 (passenger rear wheel well) to winch contactor (front bumper)
Related Documentation¶
- AUX Battery Distribution - Winch and compressor power
- SafetyHub - Winch trigger and compressor fuses
- SwitchPros - Compressor and locker control