Refreshing the TJ - Build Thread

[GP'd]

This is a build thread for my ever evolving rig to keep myself motivated and to share thoughts and ideas related to this hobby.

I purchased this truck in 2007 as a stock 2000 TJ Sahara at around 60,000 miles and presently have around 135,000 miles on the ticker. Through needed maintenance I have begun upgrading the truck and ended up with a reliable vehicle that has taken me many places. Unfortunately, most of the suspension is factory and thousands of miles on fireroads and trails have taken its toll.

The plan is to replace and upgrade the entire suspension to ensure continued reliability, easy maintenance and address some weak points and downsides of the drivetrain while everything is torn apart. Clearly this list of modifications will not happen overnight, but I have built or am building most of the components out of the vehicle. I hope to keep this Jeep low and lightweight, yet have the capability to carry a comfortable load for extended trips for 2 people. Though it currently does that now, much needs to be addressed for what I picture as my ideal Overlanding TJ.

-Gianni

Note: I will do my best to reference locations purchased and part numbers of components I have picked up. If there are issues with these links or they are broken please let me know. I will also do my best to reference other builds and informational resources as I address them in the tread.

2000 Jeep Wrangler TJ - Before

Chassis
Frame / Chassis : Factory
Cage : None
Overall Wheel Base : 93.25”
Overall Length : Front Hitch to Tire ~160.00”, Front Hitch to Rear Hitch ~155.0”
Belly Pan Clearance : ~12.50 “ (lowest point of bottom skid)
Overall Height : ~79.00” (Highest point rear rack unloaded)
Wheel Track Width : ~59.25
Overall Weight : TBD
Front Shock Travel : 8.00"
Rear Shock Travel : 6.75"

Powertrain
Engine : Factory 4.0 Liter, Precision Auto Injectors (99Jeep4Upgrade), Flow Cooler Water Pump (1750)
Batteries : Optima Red (Part Number is faded)
Radiator / Fans : Flex-a-lite Puller (485)
Air Intake : Factory Intake, K&N Filter (33-2114)
Exhaust : Factory
Muffler : Factory
Transmission : TF999 - 32RH
Torque Convertor : Factory
Transfer Case : NP 231 J
Transfer Case Shifter : Factory
Fuel Containment : Factory

Body / Interior
Body / Body Panels : Factory
Body Modifications : Dents & Scratches
Skid plate / Material : Factory
Hood / Grille : Factory
Top : Factory Hardtop
Armor : Factory
Dash / Gauges / Switches : Factory
Steering Column / Wheel : Factory Tilt
Pedal Assembly : Factory

Drivetrain
Front Suspension : Factory Coils, Teraflex 2” Spacer (1245200) - Purchased Used
Front Shocks : Bilstein (24-024426)
Front Sway Bar : Factory, JKS Quicker Disconnects (20301)
Front Bump Stops : Factory w/ Homemade Extensions
Front Axle Housing : Dana 30
Front Locker : None
Front Ring & Pinion : 3.07
Front Differential Cover : Factory
Front Axle Shafts : Factory
Front U-Joints : Factory
Front Brakes : Factory Components, Crown Industrial 5 Layer Hoses (12706.422), EBC Yellow Pads (EBCDP41255R), Centric Premium Front Disc (CE120.67045)
Front Steering Setup : Currie HD Tie Rod System (CE-9701)
Front Driveshaft : Factory
Rear Suspension : Factory Coils, Teraflex 2” Spacer (1245200)- Purchased Used
Rear Sway Bar : Factory
Rear Shocks : Bilstein (24-024433)
Rear Bump Stops : Factory w/ Homemade Extensions
Rear Axle Housing : Dana 35
Rear Locker : Factory LSD (rebuild after blowing up clutches)
Rear Ring & Pinion Ratio : 3.07
Rear Differential Cover : Factory
Rear Axle Shafts : Superior Dana Rear Axle (SAG-PA5947A, SAG-PA5947B)
Rear Brakes : ZJ Disk, Crown industrial 5 Layer (12706.422), EBC Green Truck Pads (E35DP61606),Wilwood Knob Proportioning Valve(260-10922)
Rear Drive Shaft : Factory
Tire Make / Size : Goodyear Wrangler Duratrac 265/75-16 Load Range E
Wheel Make / Size / Bolt Pattern : Factory - Rubicon 16x10 - 5 x 4.5

Body / Interior
Seats / Harnesses : Factory
Electronics : Center Dash Mount Acer Aspire One, Garmin GPS Puck
Lights Interior : Factory
Lights Exterior : 4 x Off-Road Truck Light (3029)
Safety - Fire Extinguisher : None
Winches - Front / Rear : None
Exterior Rack : Garvin Wilderness Rack (34098)

Before Front :

Before Side :

[/SIZE]
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2000 Jeep Wrangler TJ -Current (4/4/2012 Update)

Chassis
Frame / Chassis : Factory
Cage : Synergy Suspension TJ Cage Kit - Proposed
Overall Wheel Base : 93.5”
Overall Length : Front Hitch to Tire ~160.00”, Front Hitch to Rear Hitch ~155.0”
[Belly Pan Clearance : 13.75” - Evaluating skid options
Overall Height : ~80.25” (Highest point rear rack unloaded)
Wheel Track Width : ~61” Front , 60.5” Rear
Overall Weight : TBD
Front Shock Travel : 11.50”
Rear Shock Travel : 10.75”

Powertrain
Engine : Factory 4.0 Liter, Precision Auto Injectors (99Jeep4Upgrade), Flow Cooler Water Pump (1750), Currie 1" Motor Mounts (CE-9200)
Batteries : Optima Red (Part number is faded)
Radiator / Fans : Flex-a-lite Puller (485)

Air Intake : Spectre CAI (9943) (Shock towers now block factory location)
Exhaust : Magnaflow Performance Catalytic Converter (50209)
Muffler : Dynomax Super Turbo (19391)
Transmission : AW4 (Modified Valve Body & Accumulators), RAD Designs Baja II Shifter - TransGo Shift Kit (T97165A)
Torque Convertor : Factory
Transfer Case : NP 231 J w/ Currie Tail Shaft Conversion Kit (CE-9069T)
Transfer Case Shifter : Advanced Adapters Cable Shifter (715543)
Fuel Containment : Factory

Body / Interior
Body / Body Panels : Factory
Body Modifications : Factory
Skid plate / Material : Factory
Hood / Grille : Factory
Top : Factory Hardtop
Front Bumper : Under Construction
Rear Bumper : Planning
Armor : Evaluating make vs buy skid options
Dash / Gauges / Switches :Compressor, Locker & Transmission Control Switch - In Progress
Steering Column / Wheel : Factory Tilt
Pedal Assembly : Factory

Drivetrain
Front Suspension : OME 2.0” (2933), Currie Johnny Joint Control Arm Set (9100), Currie Johnny Joint Track Bar (CE-9120TJS)
Front Shocks : FOA 2.0 12" Reservoir Shock - Medium Compression & Light/Medium Rebound (FOA-12), Extending Shock Mounts - TBD
Front Sway Bar : Factory, JKS Quicker Disconnects (2030)
Front Bump Stops : TBD
Front Axle Housing : Dana 30, Superior Front Axle Tube Seals (EV70FSL)
Front Locker : ARB Air Locker ARB (RD100), ARB High Output Compressor (CKMA12)
Front Ring & Pinion : 4.56
Front Differential Cover : ARB Differential Cover (0750002)
Front Axle Shafts : Factory
Front U-Joints : Factory
Master Cylinder: Factory
Front Brakes : Factory Components, Crown industrial 5 Layer (12706.422), EBC Yellow Pads (EBCDP41255R), Centric Premium Front Disc (CE120.67045)
Front Steering Setup : Currie HD Tie Rod System (CE-9701)
Front Driveshaft : Factory
Rear Suspension : OME 2.0” (2942), Currie Johnny Joint Control Arm Set (9100), Currie Johnny Joint Track Bar (CE-9120R)
Rear Sway Bar : Factory
Rear Shocks : FOA 2.0 12" Reservoir Shocks - Medium Compression & Medium Rebound (FOA-12), Synergy Suspension Coilover Bracket (PPM-5001)- TBD
Rear Bump Stops : TBD
Rear Axle Housing : Ford 8.8
Rear Locker : Factory LSD
Rear Ring & Pinion Ratio : 4.56
Rear Differential Cover :TBD
Rear Axle Shafts : Factory
Rear Brakes : Ford 8.8 Explorer Disk, Crown industrial 5 Layer (12706.422), Wilwood Knob Proportioning Valve (260-10922)
Rear Drive Shaft : TBD
Tire Make / Size : Goodyear Wrangler Duratrac 265/75-16 Load Range E
Wheel Make / Size / Bolt Pattern : Factory - Rubicon 16x10 - 5 x 4.5

Body / Interior
Seats / Harnesses : Factory
Electronics : Center Dash Mount Acer Aspire One, Garmin GPS Puck, Yaesu (FT-1802M/E)
Lights Interior : Factory
Lights Exterior : TBD
Safety - Fire Extinguisher : None
Winches - Front / Rear : Warn HS9500i w/ Expedition Portal Edition Viking Line
Exterior Rack : Garvin Wilderness Rack (34098) - Possible Change

Parts Laid Out Before Starting (Few Months Ago):

 

[GP'd]

Ford 8.8 Build - Will add details as it progresses

Ford 8.8 31 Spline, Disk Brake, 3.73 w/ LSD - As pulled from junk yard.

Brackets Starting to go on:

Not the greatest welds, but they'll keep the tube from spinning

Setting up the Ring and Pinion

Bolting the Carrier to my mill table because I couldn't get enough torque on the bolts.

Makeshift Bearing Press w/ a HarborFreight Tubing bender and my factory jack

Checking Backlash (had to pull the pinion and back it out one more time after this photo)

 

[GP'd]

AW4 Rebuild - Valve Body Mods

AW4 - When I brought it home

Being Pulled Apart

Bolt Reference Image

Making sure I know where each bolt goes back

Valve Body Pulled

Accumulator Control Reference Image

Accumulator reference Image

AW4 Wiring taken out of the storage box for harness planning.

 

[Mr. D]

I like your reference diagrams.

 

[GP'd]

I like your reference diagrams.

Hah, thanks. I've lost, misplaced and put bolts in the wrong way enough times that I ended up finding a system that works for me. Cardboard and camera!

 

[Nigel Caffiene]

Looking forward to your build progress Gi. I, as well, like the bolt diagrams. Good Luck!

 

[GP'd]

Dana 30 cleaned up and ready to swap knuckles from my current axle.

8.8 Painted w/ brake brackets on (Reversed for shock clearance). Waiting to swap brakeline over from the D35. Sure wish ARB made a cover for this. Does anyone have any suggestions for a durable diff cover with drain hole and dipstick?

 

[bldeagle10]

im glad to see you cleaned up everything before you put it back in. thats one of my major pet peeves. i cant stand when people throw a dirty old axle or really anything dirty under their rig. nice build up, i shall be subscribing and following this!

 

[goldenbeagle]

Im standing by...looks like a solid build in progress.

 

[mochodurazo]

So organized, great build up.

 

[GP'd]

im glad to see you cleaned up everything before you put it back in. thats one of my major pet peeves. i cant stand when people throw a dirty old axle or really anything dirty under their rig. nice build up, i shall be subscribing and following this!

Thank you. Pet peeve of mine also, though I can't say I'm doing it to the fullest extent I want. Initially starting this project my intent was to upgrade or replace everything while it was apart. Budgetary constraints quickly shoot those ideas down though. New transmission clutches, ball joints...etc... add up fast! Though those and other components still have life left I wanted to do it for peace of mind to start this new drivetrain at 0. The fiscal peace of mind won on this one!

Im standing by...looks like a solid build in progress.

So organized, great build up.

Thanks guys!

 

[GP'd]

Today my plan was to put the new valve body gasket & shift kit into the AW4. Unfortunately both parts ordered were wrong. Time to deal with returns and hope I get the right part the next time.

In lieu of transmission work, I started making some real progress today. Just pulled the D35 out of the back. Time to mock up the 8.8 out-boarded Shock Brackets and attach brake lines.

Measurement of old set up D35 at full droop - Shocks attached

Measurement of old set up D35 at full droop - Shocks removed

Axle Out

 

[GP'd]

Was able to install the 8.8, Currie short arms/rear track bar and removed the factory coil spring upper mount. The brackets will be reused and relocated a few inches to the rear correcting the coil spring contour under compression... I then took all of my compressed, extended and ride height measurements and will be ordering shocks this week for the final out boarding process steps. I also need to run brake lines to the calipers.

You can see that the brackets on the 8.8 have the calipers to the front. This is reversed from factory to clear the shocks in the rear. I am able to run the extended braided cable (listed in the first post) to the 8.8 in the rear with the TJ mounting hardware, however, it is installed backwards and the crimp/hose connection to the distribution block seems a bit exposed from rear rock damage oriented this way. Searching for plumbing alternatives...

 

[GP'd]

After work today I decided to get a head start on a long weekend of brake plumbing, pulling the transfer case and tranny and whatever other projects I can do while I wait for shocks and a few other parts.

I decided to pull the fenders so that I could gain access to the front shock towers for modification and so that I can replace my bent fenders and start on my homemade highline fenders. I also hope when this is apart to relocate some critical electronics (Computer & Fuse box) in a waterproof case elsewhere under the hood. (Thoughts/Recommendations welcome)

DS Fender Pulled

PS Fender Pulled (Getting Dark)

 

[GP'd]

Pulled the transfer case this morning and began tearing it down to install the SYE

Stuck at this stage until I fix my compressor which for some reason won't turn on.