I also run an 03' TJ 5 speed 4.0L. Initially, the guy who owned it before me had absolutely no idea what he was doing (4" BL?!, sagging Teraflex springs, the list goes on), so I ended up spending a pretty penny to rip all his crap off and start from scratch and do it right, repairing the damage he had already done.
Mine is a 50/50 "Mudcrawler"/Expedition build. 3" Suspension, 1" BL, 1" MML, 1" T-case drop, with Mickey Thompson 33" 12.5 Baja Claws, adjustable front track bar, with rear track bar bracket, 2" Daystar bump stops in the front with bump stop extensions in the back, progressive springs, the works.
Now that suspension is squared away, and after I get some armor (skid plates, rock sliders), and a winch, next on the list is drive-train.
I'll be getting rid of the T-case drop and getting a tummy tuck, with SYE and CV shaft, dropping a Rubicon D44 in the back, with 4.10 gears, an E-locker in the back and an Aussie up front.
So far, just with the suspension modifications, open axles and 3.07 gears, I can handle 3's with little trouble short of some "redneck pinstripes" here and there. And that is fine by me, not being built as a full-on rock crawler.
I'm thankful that I have more of the ExPo bug than I do the Rock bug, because once you go past the 4" lift range, it becomes a new ball of wax, a really expensive one. If you want a strong ExPo Jeep, you can become quite capable with mainly suspension upgrades and very few drive train modifications, as long as you stay off the skinny pedal and let 4Lo do all the work for you when the going gets rough.
For strictly an ExPo Wrangler with an impressive amount of capability and 33" tires, I suggest the following:
- No more than 4" lift - If you go higher, you're looking at CV shafts and SYE's. 2.75 - 3" suspension, with a 1" BL is the way to go and will give you plenty of clearance.
- Adjustable Front Track bar with Rear Track bar Bracket
- 1" MML
- 1" T-case drop (Note: This may not be necessary. Some folks have been able to get away with just the 1" MML without needing a T-case drop)
- Rock-sliders, gas tank skid
That's it. With a little driving skill thrown in to boot, you can ExPo most anything, and handle up to 3's if you want to do some crawling. Just be cautious and get ready to back off the skinny pedal or you'll be getting towed home if you've got a D35 in the back.
Now, I strongly recommend the following at some point if you find yourself ExPo'ing on a regular basis:
- 8-10,000lb Winch
- Tummy Tuck - CV shaft and SYE
- T-Case skid
In closing, be ready to bend your shifter, re-adjust your linkage, and maybe even cut an inch or two off the bottom of your lower shifter tunnel if you get a BL. Trust me.