Refreshing the TJ - Build Thread

[bob91yj]

Looking good. I wish I outboarded my shocks when I went through my last round of upgrades.

I'd put the track bar in and cycle the suspension to make sure you have no clearance issues. My junk about drove our crew chief crazy when he put my Jounce bumps in. He kept having to re-rack the Jeep because it walked over a bit with each suspension cycle. One of these days I'm going to get rid of the track bar with a three link or triangulated 4 link. The factory 5 link design sucks at speed in the dirt.

I've heard good things about FOA shocks. I'll be interested to see what you think of them.

 

[GP'd]

I would love to see your ideas for relocating the fuse box and computer.

Matt, will do! Sooner I get through this drivetrain stuff the sooner I can focus on what I would consider more overland related projects!

I'd put the track bar in and cycle the suspension to make sure you have no clearance issues. My junk about drove our crew chief crazy when he put my Jounce bumps in. He kept having to re-rack the Jeep because it walked over a bit with each suspension cycle. One of these days I'm going to get rid of the track bar with a three link or triangulated 4 link. The factory 5 link design sucks at speed in the dirt.

Today I am going to mock up a mount to fit between the outboarded bucket and the re-positioned upper coil mount. Suspension will be cycled and tested before final welding.With coilsprings retained, I don't think I should have any major binding in that 10.5" of travel.

I've heard good things about FOA shocks. I'll be interested to see what you think of them.

I have too and the price was right. I'll do a mini review of them on the packaging cosmetics shortly, followed by the real information after the Jeep is back on the road.

 

[jscusmcvet]

Are you happy with the Garvin Wilderness Expedition Rack? Thanks, John

 

[GP'd]

Are you happy with the Garvin Wilderness Expedition Rack? Thanks, John

Yes, I am happy with the Garvin Rack. I have used it a few times for 'Overland' Purposes, however, most if its use comes as a lumber rack or furniture moving rack.

Only thing that has bothered me is that after moving to the San Francisco area the powdercoating has started to bubble and allow rust underneath. I guess that comes from living a 1/2 mile from the ocean.

 

[GP'd]

Been pretty busy with work and other hobbies lately but everything is slowly moving along. This coming weekend is going to be another one of those 16 hours on Sat and 16 hours on Sunday type weekends. I'm tired just thinking about it.

Tomorrow I hope to clock the transfer case and get it back together and painted.

A few things I have gotten done :

AW4 cleaned up and painted Chrysler Red, Neutral Safety Switch Rebuilt and new plumbing started. Photo makes the transmission look a bit oranger than it is. It is a nearly identical match to the ARB diff cover.

 

[Scott Brady]

Gianni,

Nicely done as always. If even some of your mad skills with the Ranger Hoodie manifest themselves in your Jeep it will be awesome!

Also nice to see how much of the work you are doing personally. You will know the truck front to back and everything in between.

 

[BigAl]

, Neutral Safety Switch Rebuilt

I love the rear shock set up, i will definitely be copying that when my rear shocks start leaking again. I have too much droop for all the more length my stock position can give.

I just grounded my park/neutral switch b/c it was so much trouble, although it did make a good anti theft device, some days i couldn't drive it:sombrero:

 

[GP'd]

Gianni,

Nicely done as always. If even some of your mad skills with the Ranger Hoodie manifest themselves in your Jeep it will be awesome!

Also nice to see how much of the work you are doing personally. You will know the truck front to back and everything in between.

Thank you for the kind words Scott! I have learned a TON about the drive-train so far in this build...especially with the re-gearing and transmission modifications.

I just hope once it is back together I will spend my time driving it, rather than trail fixing it.

I love the rear shock set up, i will definitely be copying that when my rear shocks start leaking again. I have too much droop for all the more length my stock position can give.

Great to hear! The upper buckets and lower shocks from Poly Performance were top notch. I'm really excited to get it on the road and see how much it changed the ride and travel.

 

[GP'd]

Changed gears today and welded the relocated coil buckets in so that I could plan the track bar mount.

 

[GP'd]

Some updated progress:

Rear Track bar bracket mocked up

AW4 Tailhousing clocked 11° for transfer case.

Template

Drilling

Completed

 

[GP'd]

32RH Dropped

Torque Converter still attached.

Now it's time to replace the rear main seal.

Does it end?

 

[GP'd]

Changed my mind mid day again. I was to tired to pay attention to the details of installing a rear main seal so I pulled the old D30 out instead.

On hour 9 in the garage today... so I'm going to go pull the arms off, clean up, make myself some food and have a beer. It's exhausting doing all of this solo.

Hopefully I'll have have more build and less tear down photos shortly!

 

[GP'd]

Beautiful night, so the D30 went in. Still have to paint the old knuckles, install them, and drill out the stock TB mount for the Currie track bar 5/8" bolt.

 

[GP'd]

Been solving front steering and suspension issues for the past 2 nights and finalizing them today.

Lets just say the combination of heavy duty components with less than a 3 inch lift and the want to retain factory bump stops causes issues.

ARB and Currie Track Bar Collision with ~4.5 " to bump stop. Time to grind away and clearance it.

Factory Diff Cover. Whats strange about a few of these collisions is the factory bumpstop doesn't protect from them...

Upper Control arm vs Lower Radiator Hose. I think I am going to cut another hose open and double wrap this section to protect it.

Axle Tube and Housing vs Oil Pan

Currie HD Steering & Currie Tie Rod - Drag Link, Tie Rod, Track Bar all touching at full bump. Minor tweaking was done and everything clears now.

Passenger Side Bump

Driver Side Bump - No wonder my oil pan is dented. Axle hits the pan before the bumpstop. My engine lift will solve this.

How I ground the ARB Cover. I have a bit more clean up to do and then I'll pant it. With this ground I am able to fully stuff both side of the axle at the same time as well as clear during full articulation. I'll post up final images when the cover is painted and everything is in.

Profile:

 

[GP'd]

Diff cover painted and installed after final grinding and clean up:

New front stance

New stance profile

New ride height with OME 2.5" Springs.

Front: 6.5" up travel, 4.5-5" down travel
Rear: 5" up travel, 5" down travel

Clearance to belly : 19"

On the rear I need to finish bending the passenger side brake line and hook up the e-brakes. Other than that it is done.

On the front, I need to start building the front shock towers so that I can run 12" shocks.

Biggest part of this build left is getting the transmission and transfer case back in and having drive shafts made. Everything else is cosmetic and can happen after the vehicle is running again.

Anyone in the bay area have a transmission jack I can borrow? I think i'm going to need to pick one up this week because the motorcycle jack I used wasn't ideal for pulling the tranny out. I would never be able to get the splines aligned well enough during reinstalling.

***Sorry about the pictures sizes jumping back and forth. I have no idea why they are doing that after uploading.