Chicago to Prescott - with a few nice stops in between.

MattScott

Approved Vendor
After months of slaving away as an intern for Expedition Portal the powers that may be realized my irreplaceable talents simply must be in Prescott. So here we go, a rather short thread, detailing the adventures of 2 guys, and later my lovely woman, driving across the country, trying to wing it, and travel off road as much as possible.

Here's the vehicle:



As you can see, it's not going to be the best thing to put nearly 2,000 miles on; so I made some upgrades before I left to ensure I had no issues with the size of the vehicle.

One of the biggest problems with the TJ, is the drum brakes on the rear. This is very noticable with 35" tires.



However, disk brakes from a Grand Cherokee (ZJ) simply bolt directly to the Jeep TJ - giving you a factory swap, this allows you to get parts anywhere when needed. When properly retrofitted with the ZJ proportioning valve, the performance is significantly better. It also acts as an insurance policy for the weak Dana 35 C-Clip axle, as the disk can temporarily hold the wheel in place to get you to a better spot.



The Dana 35 axle worries me, I do not want to be stuck somewhere with a broken axle. Until I do an axle swap, which will most likely be a Ford 8.8, I decided to install Alloy USA axle shafts.



I also tried to install a Spartan Locker.



I found out after I had my spider gears out, that you have to remove the carrier if your gears are higher than 4.11's. This was outside of my skill set, so I decided to wait, until I can have someone more qualified help me.

After a few midwest winters, the factory Jeep gas tank skid plate, which was wimpy to start with, was held together with rust and mud. To solve this problem, a heavy duty unit was added.



The steering linkage on the Jeep TJ is also nothing to write home about, it is hollow tubing, with tie rod ends of mediocre strength.



This is obviously something I wanted to change, however, I did not want to go to a rock crawling setup with heim joints. I found my happy median by doing the well known, Grand Cherokee V8 swap. This gives you factory parts, made of a larger diameter, solid steel. The tie rods are also significantly bigger. I sourced my kit from Crown Automotive, with a new steering stabilizer for under $200.







The Jeep TJ, doesn't have the greatest fuel range, especially with my particular Jeep, fitted with 4.56 gears, and an automatic transmission. The easy solution was to carry a jerry can. However, the Jeep TJ also does not have the greatest amount of space on the inside. I found a unit from Jeeperman Products, that is a universal can mount, for swing-out bumpers.



I also found a unit that allowed me to mount my Hi-Lift jack to my swingout bumper as well.



In addition to this, I also replaced the front calipers, pads, and rotors, sensors, and the usual myriad of tune up items.

Onto the trip.... which starts in an hour.

Our idea is to head west, we only have a few deadlines, I've told the team I'll be arriving in Prescott on the 10th, to get the keys to my new place, and to get to work at Prescott HQ. For complicated reasons of cancelled flights, and vouchers for those flights. Abby, my long-term girlfriend, is flying into Las Vegas.



She says that she'll kill me if I am not in Las Vegas by 8pm on the 8th. I think she means it.

In between Chicago, and Prescott - by way of Las Vegas, we're hoping to hit some pre-season turns in Colorado at Arapahoe Basin, find a nice hotel to stay in on our cheap budget, and then make our way to Moab for a day of adventure. Mind that we have to do this before 8pm on the 8th, or you'll no longer be enjoying the front page articles I bring you, you do check the front page every day, don't you? :)
 

MattScott

Approved Vendor
Headed west with David Studer (dstuder) in his 04 Discovery.

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MattScott

Approved Vendor
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Here's a random bar in the middle of one of Iowa's Native American Reservations. It was interesting to say the least.
 

dstuder

Observer
It was great hanging out with you and John part of the way. Sure made my trip go faster. Good luck with the rest of your trip. Safe travel and have fun!
 

MattScott

Approved Vendor
It was great hanging out with you and John part of the way. Sure made my trip go faster. Good luck with the rest of your trip. Safe travel and have fun!

I definitely enjoyed the company!

Decided to stop for the night outside of Grand Island, NE
 

MattScott

Approved Vendor
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We had a horrible vibration and howling under deceleration on the Jeep and decided to replace the front U-Joint. Got the job done in 15 minutes.

However, the howling under deceleration is still there. I think nearly 1000 miles on a worn U-Joint wore out the pinion bearing which is causing the whine.
 

Christian P.

Expedition Leader
Staff member
Matt

I will most likely be in Vegas on the 9th in the afternoon, and then drive to Prescott in a rental car that same night.
 

MattScott

Approved Vendor
When we set off today, we knew we had pinion bearing issues - however pulling out front driveshaft was not a possibility at our hotel. We decided to drive to Dillon, Colorado, and find a place to pull it there. On the way there - We had serious issues. There were loud, binding noises from the front end. It only occurred under braking, or periods of deceleration. We were able to limp to a power wash station, protected from the wind, and pulled the shaft in 15 minutes. However, it didn't fix the problem, and we had to limp our way to Dillon, where we found a Walmart and a Napa. This is when we realized we would have to tear apart the entire front axle to avoid damage.

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We decided that pulling the carrier was the best option, so we could remove the ring gear. Therefore the pinion could not spin, and possibly seize and cause significantly more damage.

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In about two hours, we rebuilt the entire front axle behind walmart; then we realized we had other problems.

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Sometime during the drive through the mountains last night, or in the drive to Dillon, 4 out of 5 wheel studs sheared off. By some grace of god, the wheel did not fall off over the mountain passes.

What really frustrates me is that these were brand new axles with less than 1500 miles on them from Alloy USA.

I was able to walk across the street and get new studs and lugnuts and press them on.

We were able to get the Jeep functional, but only 2WD. We rewarded ourselves with a couple of cold beverages at the Dam Brewery. Thanks for the recommendation David!

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We obviously can't do any trails in Moab now, so we are heading straight for Prescott in the morning.
 
Last edited:

Ray Hyland

Expedition Leader
Spoke to Matt this morning, he is enroute to Prescott with 2WD, and has a mix of rain and snow in the forecast for his drive down today. Looking forward to seeing him here in the office tonight.
 

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