Did the brake light switch upgrade that's been talked about again/recently on SS (removing the hydraulic switch from the front of the airpack, and installing an air-actuated switch to the left/air side of the airpack). I know there are already many threads about this, but the "Upgrade Kits" that have been used seem to be getting hard to come by, so I'm posting with the parts listed out for those who'd like to make their own kit (list of parts below). The outside diameter of the air line on the airpack needs to be measured before ordering parts, as the line OD determines which brass elbow needs to be purchased. Also, a person may be tempted to use a brass plug to replace the hydraulic switch... DON'T! Brass plugs tend to be hollow, and aren't capable of handling near the pressure of steel plugs (especially if one is milled a little thin on the end). So, use a STEEL plug. As far as the wiring goes, some folks would just cut the existing plug off the truck's harness, and crimp on a couple of ring terminals to slip over the air switch posts, but I like things to be more insulated and protected. The wiring parts shown are just a suggestion, and are what I used because they're what I had in the shop. The blue sleeves over the switch posts are 14-16 ga. insulated female bullet connectors, loaded with dielectric grease, and pressed onto the posts (they're not coming off without a fight). Then I just made up 2 jumper wires with insulated plugs to crimp and shrink-tube onto the bullet connectors.
Removed the Hydraulic switch from the front of the airpack, and replaced it with a 1/8-27 NPT Socket Head Plug. Before and after;
Cut off the old electrical plug, and replaced it with connectors to match what I put on the new switch;
Removed the air line and fitting from the left side of the airpack, installed the new fittings, installed the new switch, and plugged it in. Before and after;
Reinstall the skid plate, bleed the airpack, and check for leaks at the new air fittings, and the plug on the airpack front, and it's done.
Parts list;
-If you have a 3/8 airpack line, you'll need a 3/8 Male NPT x 3/8 compression elbow
-If you have a 1/2 airpack line, you'll need a 3/8 male NPT x 1/2 compression elbow
-Haldex BE13250 Switch
-3/8 Male NPT x 3/8 Female NPT x 3/8 Female NPT "Street Tee" or "Run Tee"
-3/8 Male NPT x 1/4 Female NPT Bushing
-1/8-27 NPT Steel Plug
-Your choice of electrical hardware to connect the two wires to the posts on the new switch