I measured the rear axle....I am not sure if it was in this thread or the S110/130 thread but I’ll put it here. so the S135 is 5in tall and 4.25 or 4.5 (can’t remember) wide. The S110/130 is 4.25/4.5 tall and 4.25/4.5 wide.
So basically the S135 has the same width as the S110/130 but the S135 is slightly taller.
S135 has 7mm thick tubes and has some weird “special” HSLA steel. Which really isn’t that special in my opinion. It cracked for me and noted it’s been an issue in the past for others.
S110 has 8mm thick tubes, unsure of steel type.
S130 has 10mm thick tubes, unsure of steel type.
I have seen and been told the S135 and S110 are both rated at 13,500 (some are derated for suspension and other crap)
The S130 on the fords is up to 14,706 lbs, I have read that they have been rated up to 16k in different applications, there’s an S14-130 and a S16-130. I’m not sure if it’s the same axle or slightly different housing or bearings or what?
I looked on rock auto and the wheel bearing part #s are all the same for the S135, S110 and S130. I am curious if the S150 used the same wheel bearings. From a strength standpoint I do not think the wheel bearings are the issue. Even the R&P was downgraded quite a bit from the S135 to the S110 and still have the same 13.5k rating. (14.25 to 12.25) from what it seems it’s all housing related.
I ran 15,500 lbs on my S135 and cracked the housing. It’s a hairline crack and have put over 5k miles on it since with no issue but my gut tells me it’s all housing related when it comes to these axle ratings. I bet I wouldn’t have even cracked mine if I unloaded some weight before hitting Boone road at the hammers. That road coming into the lakebed has some nasty bumps and holes since it’s a dirt road but I’m sure one jarring hit cracked it, it was probably fine on the highway.
So what’s the ideal setup in my eyes? An S150 if the wheel bearings are the same as the S135. You get a MASSIVE 14.25in ring gear. You get the thicker housing with the S150. If the wheel bearings are the same the swap would be easy. I noticed the manufacturer doesn’t even weld most of the brackets. They all wrap around a boxed housing and use clamping force to keep stuff in place. Most brackets are welded for about 1in in one spot. So swapping brackets onto an S150 housing would be easy.
Some say you can’t weld to this bullshit “HSLA” steel without special methods but I found a bulletin from ford stating you can mig weld up to 45 seconds on HSLA housings. I’m not sure if it’s 45 seconds total or at one time. Even at 45 seconds total, you have like 5-6 1in beads to make all in different spots. That probably wouldn’t add up to 45 seconds.
Another thought is if you have an S135 housing and your gonna overload it just gusset the spring perch like a little truss. The cracks happen right at the perch where all the weight is.