2003 KJ Limited Build in Progress

[the_dealer]

Since I've been frequenting here more, I thought I would start a build log. After all, my KJ is the family expedition rig. I'll keep the mod list updated so it will be easy to keep up.

OME 926/947 MD coil springs
3/8" clevis lift
Moog HD K3199 Lower BJ
Moog UCA, Inner/Outer Tre's, Sway Bar links, Rear UCA bushings & BJ
Detroit Axle Reman'd steering rack
Crown front LCA's
Bilstein struts
Bilstein rear shocks for Dakota CC 4wd
Mopar rear LCA'S
Powerstop rotors/pads


Real quick summary: had a nicely built TJ that was totaled by a drunk driver. I needed a DD to get me and the family around while I looked for an LJ and swapped stuff over. My sister had a KJ that took a very light hit to the passenger side trying to avoid a deer. They thought there was some frame damage since it wouldn't align to specs, so I picked it up for $500. 180k'ish miles and bone stock.

Here she is the day I brought her home

About 2 weeks after buying it, I noticed something dripping off the front bumper. There was a hairline Crack on one of the radiator endcaps (common problem). I decided to skip the cheap radiators and get an oem one from the local radiator shop.

After a visit to a frame shop, the results were a tweaked clevis and bad tre causing the problems. No worries it was all about to get replaced. I did a complete replacement of the suspension and steering, and replaced all bushings (whether they needed it or not). My goal is simple: be a reliable rig to DD and wheel, but be decently capable offroad. Looks are important, so I wasn't going to start hacking it up. I knew I'd have an LJ to do the harder wheeling. I didn't realize how bad the suspension was until I started replacing stuff. It sat almost 2" lower than factory new height, due to the infamous KJ sag.

Part Collecting

 

[the_dealer]

Worn out factory junk

My little helper getting the rear coil seated

New Goodness

New Mopar LCA'S

Here's the results. I decided to run the factory sized tire until they wear out. They had very few miles on them, and I was starting to go broke. I now had 2 jeep habits to fund.

I noticed that there was some pretty ghetto wiring going on out back, and after following the wiring, I found it was for the trailer wiring. My KJ was towed behind an rv in a past life, so there was 20ft of ghetto running from the front to the rear. Pretty sure this is why my alternator took a dump. This is some type of converter

I have pictures stored everywhere, and I'm still trying to get them all in one place. I'll post more and try to keep this somewhat organized. I'll be adding to the progress this weekend as I do some more mods.

 

[the_dealer]

After spending as much as I did on the suspension, I needed to do some of the cheaper mods for a while. I had this modulator that never made its way into the TJ, and decided to put it in the KJ.

I didn't like any of the options available to mount my cb antenna, and definately wasn't wanting to drill any holes to mount one. I decided to drill the factory fender mount and tap it to work with my antenna. I did have to do a little trimming on the cover, but it came out clean looking. My fm reception is better, and I have a factory looking mount

 

[the_dealer]

After I did the OME and most of the suspension, I had a good bit of seat time in the KJ. One thing I despised was the sloppy unpredictable shifting of the 42rle. After some research, I decided to add the Transgo shift kit and replace the filter. I also used amsoil since I'm starting to slowly convert over. I made an error with check ball placement and ended up wasting 8 qrts of Amsoil, which made my wallet even lighter. Here's the only 2 pics I snapped due to not wanting to get my phone covered in atf.

BTW Chrysler's design of the 42rle and accumulator pistons is retarded. Its like a circus act trying to get everything back together. I was happy with the results of the Transgo kit, even though it wasn't quite as firm as I was hoping for. I also repaired my missing bushing in the 4wd linkage, and replaced the T/C end RZEPPA (sp?) joint on my front ds. Jeep sells the whole shifter assembly only. I was able to use a JK bushing as the clip, and mod a rubber flange nut from ACE (which works flawlessly). Grand total=$8.34

Shortly after that I broke one of the ears on the rear ds slip yoke wheeling on my property. I was having a hell of a time finding a replacement, and a fellow JF member happened to have an extra. I hope to do an SYE in the near future.

Since I recently bought an audio shop, I somewhat have to run some decent gear. This might not interest some of you guys, but I'll include it anyways. I spend a lot of time in my rig, and I've always enjoyed a decent sound system. Since my KJ will be hauling gear, I wanted to get the most I could while taking up the least amount of space. I decided to go with an American Bass XD 8" sub. The box is fairly small, at 16Wx12Hx17D. The terminal lugs I used now have wing nuts, so it can be quickly removed without tools. The amp is a PPI Phantom P1000.1, which I have set to give the sub around 500w(amp rated over 1kw). When I turn the box so it's firing up, I lose very minimal cargo room.

I also installed a PPI component set up front and alpine type s coaxials in the rear doors(also amped, amp hid under dash). I used 3/4" mdf to add some mass to the door skin to help with the midrange. The gray stuff is non-hardening putty.

Here's a little teaser of what's going to be installed soon.

 

[DetroitAxle]

Since I've been frequenting here more, I thought I would start a build log. After all, my KJ is the family expedition rig. I'll keep the mod list updated so it will be easy to keep up.

OME 926/947 MD coil springs
3/8" clevis lift
Moog HD K3199 Lower BJ
Moog UCA, Inner/Outer Tre's, Sway Bar links, Rear UCA bushings & BJ
Detroit Axle Reman'd steering rack
Crown front LCA's
Bilstein struts
Bilstein rear shocks for Dakota CC 4wd
Mopar rear LCA'S
Powerstop rotors/pads

Where's the picture of the Rack? :Mechanic:

 

[the_dealer]

Haha I'll snap one in a few.

 

[GetOutThere]

Always had a soft spot for the KJ, and I like your progress so far.

 

[the_dealer]

Here's a pic of the rack. The lines aren't leaking, it's just where I made a mess. I actually sprayed it down with simple green and cleaned it up a tad. Being the smooth tool operator that I am, I was able to Jimmy the old rack out of the passenger wheelwell, and do the same to get the new rack back in. The swap took less than 3hrs, which includes some beverage consumption and bs'ing around


Getoutofthere, thanks for the compliment. I used to be anti-kj, but after owning it I can say my opinion has changed. I love the thing!

Back to it, today I ordered an upper strut spacer from JBA. It will put me right at max lift for the KJ and stock cv's. I also ordered some Reman'd cv's and unit bearings from Detroit Axle, which will go in as soon as I get the gears set up. I'm trying to decide if I want to buy a lower profile roof rack, or come up with a mount to put my Surco on. I hope to get an arb front bumper as well, and some Rock Lizard sliders are high up on the list. I decided to replace a bunch of things that needed attention and have a reliable rig, versus having a bunch of cool mods but always worrying about making it back home. I'm also toying around with a freezer/fridge. If the weather stays decent, I'll have some more progress pics coming.

 

[the_dealer]

I'm always trying to do free and low cost mods in between the expensive ones, whether for looks or for function. I decided to de-badge her for a cleaner look. I snapped these pics today since I haven't taken any since doing so. I cut the grass in my field just so I could take y'all a good pic or 2 lol.

 

[tommudd]

I see you are here as well ha ha
Good pictures

 

[Singlespeed92]

That's a good looking KJ,my friend! I always liked the looks of those LOL,on the mowing for a good pic,I do that too

 

[the_dealer]

Thanks a bunch man! It's starting to come along pretty good now that the "repairs" are out of the way. Now I can't start doing all of the "cool" mods. Actually have plans of taking her out for the maiden voyage July 4th weekend. The trails will be a big challenge for the KJ, but I'm determined to hang with my buddy's XJ with 3.5" IRO on 31's. I have an advantage...about 10 more yrs of experience lol

 

[the_dealer]

Picked up a little something off craigslist. I was looking for some parts for my boat, and came across this for $150. Ended up getting it for $125, and that's a steal!! Going to redo the walls so there are higher, diamond plate aluminum flooring/walls, and ditch the tailgate and fab up a cj style fold down(which will double as a cooking top). I hope to get an rtt on it as well. Definately going to need some work, but it's pretty solid and only has light surface rust. I'm going to have to flip the axle to get it up some more, and hopefully run my 235's on it when I get new tires

 

[the_dealer]

Got my top plate spacers today, hopefully I'll get them in when I get back from wheeling this weekend. I gotta hurry and decide on some tires, I plan on doing something next week.

 

[tommudd]

That should make you a nice little trailer
But you'll need bigger tires, I'm running 265-70-16s on mine now, looking to go bigger :Wow1: