Bizron's YJ Build-up

[bizron]

I've recently obtained a trail rig!

1990 Jeep Wrangler (YJ).
4.2 L 6-cylinder with 120 K miles - seems to run good so far
5 speed
33 x 12.50 x 15 tires (needs new ones)
lots of rusty parts/holes

Jeep07 is helping me complete a SOA conversion that was attempted by a previous owner.

http://lh5.google.com/image/bizron/RiraODr-0pI/AAAAAAAAA7c/UkWm3mbDPOo/s800/S4012430.JPG

I'll post updated pics when I have some.

Thanks for looking!

[Monstero]

Are those Eye Bolts on the front bumper???

[Gordon]

Off to a good start, Byron. Looking forward to seeing ya on the trails. And, I'd tweak that front bumper a bit.

[bizron]

Are those Eye Bolts on the front bumper???

yeah they are lol

Wesley has already torched off the rear two haha.
http://lh6.google.com/image/bizron/RiraiTr-01I/AAAAAAAAA88/8pDINeF8bkY/s800/S4012442.JPG


Gordon - what would you do to the bumper? just shorten the width?

[Hokie_YJ]

I'd make Wes build me a new bumper. :lol:

[bizron]

I'd make Wes build me a new bumper. :lol:

Have you seen the one he built for himself? It looks really nice. You may be on to something there! :grin:

[bizron]

Here are some pics of the axle cleanup.

There was a lot of left over metal from the other soa attempt, so it all had to be ground down.

http://lh6.google.com/image/bizron/RiravTr-09I/AAAAAAAAA98/7xXFNMB2Q8E/s400/S4012450.JPG

http://lh3.google.com/image/bizron/Rirawjr-0-I/AAAAAAAAA-E/fGgfN1-OWfM/s400/S4012451.JPG

http://lh5.google.com/image/bizron/RirayDr-0_I/AAAAAAAAA-M/bMl0ZAPHNNo/s400/S4012452.JPG

http://lh6.google.com/image/bizron/RirazTr-1AI/AAAAAAAAA-U/8VjYMFm02JY/s400/S4012453.JPG

Grinding the old welds, on the top and the bottom of the axle was slow going but it turned out nice.
http://lh5.google.com/image/bizron/Rira2Dr-1CI/AAAAAAAAA-k/6NVlSfR0s_M/s400/S4012455.JPG

http://lh5.google.com/image/bizron/Rira5Dr-1FI/AAAAAAAAA-8/n_-qysjD6dY/s400/S4012458.JPG

http://lh6.google.com/image/bizron/Rira9Tr-1II/AAAAAAAAA_U/6ecKfoglEsY/s400/S4012461.JPG

http://lh5.google.com/image/bizron/RirbCDr-1MI/AAAAAAAAA_0/GI8_RsZ5L7U/s400/S4012465.JPG

It felt like it took forever, but the axle is finally good and smooth now :-)
Hopefully the rear perches will be welded on soon and I can bolt the rear back up.

[Gordon]

Byron, I'd go ahead and go with something new. If you're planning a winch, fab for that now, even if you don't actually install a winch until later. You want a bumper that will accept "D" shackles. There are a lot of great ones here in this group. Just search the projects thread and get some ideas.

[bizron]

test fitting the rear perches on top of the axle, then tacked on.
http://lh6.google.com/image/bizron/Riw0xzr-1VI/AAAAAAAABA8/nn1HqQWaBEI/s400/S4012474.JPG

tacked
http://lh4.google.com/image/bizron/Riw0_Tr-1eI/AAAAAAAABCE/5d_ynY-SFWI/s400/S4012483.JPG

http://lh3.google.com/image/bizron/Riw1FDr-1iI/AAAAAAAABCk/cbh0wbr_uuY/s400/S4012487.JPG

welded on - nice welding Wes!
http://lh5.google.com/image/bizron/Riw1Jjr-1mI/AAAAAAAABDE/XB27sVEURGE/s400/S4012491.JPG

http://lh6.google.com/image/bizron/Riw1Kzr-1nI/AAAAAAAABDM/uLocBOkcxvI/s400/S4012492.JPG


back under and tightened up! that looks better!
http://lh3.google.com/image/bizron/Riw04Dr-1ZI/AAAAAAAABBc/SyrNEm7Oj9k/s400/S4012478.JPG

this is a before shot to compare
http://lh6.google.com/image/bizron/RiraITr-0nI/AAAAAAAAA7M/VuQ_nVQKeak/s400/S4012428.JPG

So far the rear spring-over is all that's done. The rear shocks have not yet been mounted and the brake lines aren't reconnected yet.
We're still working to figure out what the best arrangement will be for the rear shock mounts.



Thanks for looking!

[Want2Wheel]

That looks alot different. It is going to look great when it is done.

[Dino1967]

kool nice work

[bizron]

Wesley cutting away the spring perches and shock brackets

http://lh5.google.com/image/bizron/Ri93VZkwz3I/AAAAAAAABGE/9tdlxG67V3c/s400/S4012514.JPG

Wesley catching the rubber bushing on fire hahaha

http://lh3.google.com/image/bizron/Ri93Y5kwz5I/AAAAAAAABGU/EQqugR04eVI/s400/S4012516.JPG


nasty metal to grind away

http://lh6.google.com/image/bizron/Ri93apkwz6I/AAAAAAAABGc/R8EcMBdpMrM/s400/S4012517.JPG

http://lh4.google.com/image/bizron/Ri93cJkwz7I/AAAAAAAABGk/yXB4L2S8OJA/s400/S4012518.JPG



all cleaned up

http://lh6.google.com/image/bizron/Ri93jpkw0AI/AAAAAAAABHM/swZf4bEzKAQ/s400/S4012523.JPG

http://lh4.google.com/image/bizron/Ri93lJkw0BI/AAAAAAAABHU/MDKsrUaGnFM/s400/S4012524.JPG




Primered and ready to be bolted back up

http://lh4.google.com/image/bizron/RjCku5kw0FI/AAAAAAAABH4/drJBI2RJECI/s400/S4012528.JPG

lifting higher to get the axle under the springs

http://lh6.google.com/image/bizron/RjCktZkw0EI/AAAAAAAABHw/n5yrR1eKH48/s400/S4012527.JPG

http://lh5.google.com/image/bizron/RjCkwJkw0GI/AAAAAAAABIA/w_4uGz-yCGA/s400/S4012529.JPG


all bolted up

http://lh4.google.com/image/bizron/RjCk05kw0JI/AAAAAAAABIY/mg-kzfrnE5E/s400/S4012532.JPG

the new stance!

http://lh6.google.com/image/bizron/RjCk8Zkw0OI/AAAAAAAABJA/PNvRNdvF8As/s400/S4012537.JPG


For comparison, check out the before and after

BEFORE:

http://lh3.google.com/image/bizron/Riw09Dr-1cI/AAAAAAAABB0/_lWtW8R7oIg/s400/S4012481.JPG

AFTER:

http://lh3.google.com/image/bizron/RjCk_pkw0QI/AAAAAAAABJQ/XlGGz4GuYJ4/s400/S4012539.JPG


Things left to do before it can be driven:


Reconnect brake lines (re-run under frame?)
Bleed brakes
Reconnect emergency brake cables
Fab up shock mounts & install shocks
Fill T-case w/oil
Re-seal differential covers & lube
Figure out what vacuum lines need to be hooked up for the 4wd actuator
Remove pitman arm and replace with the 4" skyjacker drop pitman arm
Re-connect steering components

The goal is to have her road ready by Saturday evening.

Thanks for looking!

[limegreenyota]

Wow your flyin on that thing!! Dont forget about the line at the master cylinder for the rear being blocked inside!! Its just the end of a vacuum plug off stuck to the end of the line!!
I think im gonna send my buddy these pics!! :twisted:

[Bluegill]

Looking good Byron! ;-)

I'd recommend extended stainless brake lines instead of relocating the stock ones, and a mechanical 4wd actuator instead of the vacuum one. :wink:

[Dino1967]

big difference nice

[Hokie_YJ]

I'd recommend... a mechanical 4wd actuator instead of the vacuum one. :wink:

I definately agree. I had a posi-lok kit on my YJ. It's a pretty easy install. They're a little pricey, but well worth it in my opinion. My vacuum motor went out on mine, and they can go out at any time. The mud and water just wreaks havoc on them.

Here's a link to the posi-lok:
http://www.4x4posi-lok.com/app_jeep.html

You'd want part #920

And here's a write-up from someone who made one himself:
http://home.earthlink.net/~stevenschreiber/cabledis.htm

I found that on another forum, but IIRC the guy who did it used to be on this board too.

[bizron]

thanks guys! :P

yeah, wes and I have been putting in a couple of hours each evening since Rob dropped it off last Saturday.

we're trying to get it done asap so I can actually drive my new toy lol

a mechanical actuator would be ideal, but I'm really going cheap in the beginning.

Instead of doing a rear locker, we may just weld the carrier. I know it won't be the best for on-the-road driving, but its cheap and effective.

thanks again for the ideas :!:

[LoOnaTik]

Wow, you guys are movin' fast!! Looks 100% better already.

[Bluegill]

Instead of doing a rear locker, we may just weld the carrier. I know it won't be the best for on-the-road driving, but its cheap and effective.


If you have a Dana 35 rear axle, you'd better re-consider that or else carry spare axle shafts, spider gears, and pinion gear with you on the trail. A locked stock D35 is simply an explosion waiting to happen! :shock:

[Derrickalda]

Instead of doing a rear locker, we may just weld the carrier. I know it won't be the best for on-the-road driving, but its cheap and effective.


If you have a Dana 35 rear axle, you'd better re-consider that or else carry spare axle shafts, spider gears, and pinion gear with you on the trail. A locked stock D35 is simply an explosion waiting to happen! :shock:

x2

[TNRanger]

If you ever do consider gears, I have a 9" the same width as your D35 that already has new 4.88s with all new bearings adn seals.

[Jazzman31]

How much do you want for thee 9 inch, Im extremely interested.

[bizron]

front drive shaft reconnected
http://lh6.google.com/image/bizron/RjXqcJkw0eI/AAAAAAAABLI/kFo6MAqPq6I/s800/S4012553.JPG

cleaned up diff cover
http://lh3.google.com/image/bizron/RjXqdZkw0fI/AAAAAAAABLQ/P7M62E0G3CE/s800/S4012554.JPG

cleaned up diff
http://lh5.google.com/image/bizron/RjXqe5kw0gI/AAAAAAAABLY/c-NzX-VqODM/s800/S4012555.JPG

brake lines re-routed
http://lh6.google.com/image/bizron/RjXqiJkw0iI/AAAAAAAABLo/tdx2dBFyVgI/s800/S4012557.JPG

wesley welding up a new rear shock mounting brace
http://lh3.google.com/image/bizron/RjiPqpkw0kI/AAAAAAAABL8/Qj_9IkuHZ8M/s800/S4012559.JPG


brake master cylinder
http://lh4.google.com/image/bizron/RjiPz5kw0pI/AAAAAAAABMk/A1ADjvQxEy4/s800/S4012564.JPG

when did they start using chocolate syrup as brake fluid? :-)
http://lh5.google.com/image/bizron/RjiP1Jkw0qI/AAAAAAAABMs/q84vDsMM0cA/s800/S4012565.JPG


all cleaned up...that's better!
http://lh6.google.com/image/bizron/RjiP3Zkw0sI/AAAAAAAABM8/q1LGQCLfd9Y/s800/S4012567.JPG

rear shock brace welded in place
http://lh5.google.com/image/bizron/RjiP7Jkw0uI/AAAAAAAABNM/sYYr-c5dTFo/s800/S4012569.JPG

rear shocks mounted (yes those are zip ties - they were used with a coat hanger to help compress the shocks during installation)
http://lh6.google.com/image/bizron/RjiQRZkw08I/AAAAAAAABO8/cySSzZkmJ-c/s800/S4012583.JPG

drop pitman arm finally installed (painted blue) and shocks mounted up
http://lh6.google.com/image/bizron/RjiQPZkw07I/AAAAAAAABO0/zHll02dPOBk/s800/S4012582.JPG

front drivers' side shock installed
http://lh6.google.com/image/bizron/RjiQTZkw09I/AAAAAAAABPE/AJYx6u1a280/s800/S4012584.JPG

front passenger side shock installed
http://lh3.google.com/image/bizron/RjiQZpkw1AI/AAAAAAAABPc/Vf5wRHzHYI0/s800/S4012587.JPG


At this point,

Reconnect brake lines (re-run under frame?) - ** DONE **
Bleed brakes - ** DONE **
Reconnect emergency brake cables -ignoring for now (just tied them away)
Fab up shock mounts & install shocks - ** DONE **
Fill T-case w/oil - ** DONE **
Re-seal differential covers & lube - ** DONE **
Figure out what vacuum lines need to be hooked up for the 4wd actuator - ignoring for now. just want to actually drive the thing
Remove pitman arm and replace with the 4" skyjacker drop pitman arm - ** DONE **
Re-connect steering components - just going to remove the steering damper for now

SO....

You'd think the jeep would be ready for the maiden voyage right? at least around the neighborhood...

well, to make a long story short, I wasn't aware that the transfer case was only mounted to the skid plate by one very loose bolt. Trying to give the jeep a little bit of gas resulted in what can only be described as someone angry under the jeep with a 16 lb sledgehammer.

As long as I was super careful on the throttle, it did ok. We later discovered the transfer case problem as well as the skid plate only having 1/2 of the bolts actually holding up the skid plate. (3 were on, 3 were just in place - meaning they had rusted out and were just dangling)

http://lh5.google.com/image/bizron/RjomSpkw1CI/AAAAAAAABPw/LDVaJerccKI/s800/S4012589.JPG

so now starts the process of actually creating a new transfer case mounting bracket. The bracket will drop down and use these mounts.

http://lh4.google.com/image/bizron/RjomgZkw1KI/AAAAAAAABQw/Iu_W41rA6gc/s800/S4012597.JPG

this is the transfer case mounting bar (note the cutouts for exhaust, front ds, etc

http://lh6.google.com/image/bizron/Rjomi5kw1MI/AAAAAAAABRA/tpyY55NH2fo/s800/S4012599.JPG

here is a shot of the mounting surface on the t-case
http://lh4.google.com/image/bizron/RjomlZkw1OI/AAAAAAAABRQ/FxCgccmZs80/s800/S4012601.JPG

We're hoping that after we fix this problem there won't be any more nasty gremlins pop up and hinder progress. After the mount is fabbed, we will need to figure out just how to do another towards the rear and mount up a home-made skid plate of some sort.

The jeep is definitely getting there. Hopefully it'll be completed soon and I'll actually get to drive it without fear of the sledgehammer guy under the jeep lol.

Thanks for looking!

[Gordon]

Lookin' good.

[r1ng3l78]

looks like you have a bit too much angle on those shocks. i'd look into that before you break something hitting a speedbump too fast. if both tires try to travel up at the same rate, the shocks will bind instead of compressing.

[TNRanger]

exactly what I was thinking.

As well as the fact that they are about pointless on such a tight angle. Dampning is decreased with angle and that's a lotta angle.

[Want2Wheel]

Progress, that is what it is. Looking good.

[bizron]

looks like you have a bit too much angle on those shocks. i'd look into that before you break something hitting a speedbump too fast. if both tires try to travel up at the same rate, the shocks will bind instead of compressing.


exactly what I was thinking.
As well as the fact that they are about pointless on such a tight angle. Dampning is decreased with angle and that's a lotta angle.

:shock:

Sounds like more gremlins to me lol.

Anybody got any better mounting suggestions? The reason they are at that angle is because they are so long. Trying to mount them vertically will just compress them too much.....seems like I may wind up buying shorter shocks and asking wesley to re-do the mounts somehow...


Sound like fun wes? hahaha :grin:

[Hokie_YJ]

I've got a couple shocks. They're brand new. They're Rusty's brand, made for an XJ but would fit your YJ fine. Only thing missing is one of the metal sleeves that goes inside the bushing. They measaure about 30'' extended, and like 17'' compressed. If they'll work for you you can have 'em for 40 bucks.

[r1ng3l78]

what was wrong with the stock mounts? usually an 8-10" shock will allow plenty of flex.

[Jeep07]

what was wrong with the stock mounts? usually an 8-10" shock will allow plenty of flex.

They are all gone from the prev SOA attempt. rear axle was missing all mounts and the frame mounts are MIA as well.

[BroncoMike]

Keep up the nice work!

[bizron]

OK

Its been a long time since I updated this build thread.

Wesley and I have ran into numerous challenges along the way with this jeep.

Right when we thought we were nearing completion, something else would always break or mess up and we'd have to fix it.

The jeep is finally getting to the point where it can be driven without fear.

Before:
Axles barely under it..
all the nuts were loose...
driveshaft not connected...
transfer case skid plate rusted out

http://lh3.google.com/bizron/RirZ-jr-0iI/AAAAAAAAA6k/dgrtiR_CI5U/s800/S4012423.JPG


After:
New tires (33x12.50x15) mounted and balanced
transfer case skid plate mounts welded in
custom transfer case mount fabbed up

Wesley couldn't help himself. He had to hop in and take it for a spin.

http://lh4.google.com/bizron/Rrfum0htSiI/AAAAAAAAB6g/qc8qmnLDZpQ/s800/S4013260.JPG

http://lh5.google.com/bizron/RrfuqEhtSkI/AAAAAAAAB6w/9Z3oYgbC47c/s800/S4013262.JPG

Wesley flexin' my jeep a little on a log.

http://lh6.google.com/bizron/Rrf19UhtSyI/AAAAAAAAB8g/KBXVYKHFxJI/s800/S4013276.JPG

http://lh4.google.com/bizron/Rrf1_0htSzI/AAAAAAAAB8o/2NeJcv58DHU/s800/S4013277.JPG


http://lh6.google.com/bizron/Rrf2VUhtS9I/AAAAAAAAB94/U86YRWf9FAg/s800/S4013287.JPG

http://lh6.google.com/bizron/Rrf2PUhtS5I/AAAAAAAAB9Y/c11-LgVZzSI/s800/S4013283.JPG

Currently there's still only two wheel drive because we haven't figured out the vacuum hose routing yet.
No lockers or anything, so it isn't super capable right now haha.

I have a custom driveshaft to install, but I need to get a SYE first. That's a little down the road unless someone has one for cheap! haha

I may try and hook up one of those home-made posi-lok kits as opposed to going the vacuum route.

Thanks for looking! Maybe I'll make it to an actual trail one of these days :P

[Gordon]

:smokin:

[BillM]

Biz, try to locate an passenger side TJ shaft for your front and you can do away with the vaccum/posi-lock junk.

[Bluegill]

;-) Looking good Byron!

[bizron]

Here's a small video of Wes wheelin' the jeep.

The quality is poor, but at least the file size is relatively small ~2MB

Jeep Trial Run (http://www.byronsalyer.com/JeepExcursion1.wmv)

Thanks for the compliments guys :smokin:

[Jazzman31]

This jeep went from junk yard bound to trail bound. Great work guys, you have inspired me to go back outside in the heat and start working on my jeep, doing the next round of mods. Cant wait to see this. Awesome
:smokin:

[limegreenyota]

WOW :shock: that thing has came ALONG ways!! GOOD JOB!!!

[Hadfield4WD]

looks decent. I have a powertrax locker for hte rear if you're interested.

[BillM]

video didn't work for me.

[bizron]

video didn't work for me.

what did it do? anything? you may want to try the right click + save target as routine

[BillM]

it tried to open up in Winamp. Gave me th file and all but just wouldn't play. I will try saving it first.

[Jeep07]

Welp we rigged the fork yesterday and the jeep has 4wd now. Also took it down the road to adv auto so i could get some yota stuff. Starting to build confidence with it in the little trips.

It took a while but byron stuck with it and now has a nice jeep on the cheap :).

Now we have to get him on some trail rides.

[Gordon]

:smokin:

Byron, whatcha feel like starting with? Easy? :grin: Or Bumpus on Saturday? :twisted:

Actually, I'd like to run Stony in a few weeks. That might be a good start.

[pplblazerdude]

:smokin:

Byron, whatcha feel like starting with? Easy? :grin: Or Bumpus on Saturday? :twisted:

Actually, I'd like to run Stony in a few weeks. That might be a good start. Id like to go on a ride with you guys before I head back to school.

[bizron]

:smokin:

Byron, whatcha feel like starting with? Easy? :grin: Or Bumpus on Saturday? :twisted:

Actually, I'd like to run Stony in a few weeks. That might be a good start.


hahaha I've built up some confidence in it now...Might as well dive in and test out the welds, right?

I may be able to work a maiden voyage into Saturday :P
The temp gauge doesn't work right now, which is a major concern for me.

I'd hate to spend all this time working on it and then blow a head or something because it overheated.

I'll know more later.

[Jeep07]

:smokin:

Byron, whatcha feel like starting with? Easy? :grin: Or Bumpus on Saturday? :twisted:

Actually, I'd like to run Stony in a few weeks. That might be a good start. Id like to go on a ride with you guys before I head back to school.

Clint when you wanna go?

[pplblazerdude]

:smokin:

Byron, whatcha feel like starting with? Easy? :grin: Or Bumpus on Saturday? :twisted:

Actually, I'd like to run Stony in a few weeks. That might be a good start. Id like to go on a ride with you guys before I head back to school.

Clint when you wanna go? Pretty much anytime is good with me. Im not doing anything really. The sooner the better though. Hate to break the day before I go back to school. That would be a mess.

[Jeep07]

:smokin:

Byron, whatcha feel like starting with? Easy? :grin: Or Bumpus on Saturday? :twisted:

Actually, I'd like to run Stony in a few weeks. That might be a good start. Id like to go on a ride with you guys before I head back to school.

Clint when you wanna go? Pretty much anytime is good with me. Im not doing anything really. The sooner the better though. Hate to break the day before I go back to school. That would be a mess.

Why not go to bumpus sat? When do you leave?

[pplblazerdude]

I already have plans for the day im pretty sure. Im not 100% if I am able I may go. I leave the 18th.

[bizron]

Hey guys,

It's been a while since I've posted in the build thread because my rig has been disabled. Most of you probably don't know that a while back I was wheeling with Jeep07 and Want2Wheel and I destroyed my stock driveshaft. The driveshaft was already weak from where the previous owner went over a rock or something and put a spiraling crease in it.

http://lh5.google.com/bizron/RigO4jr-0HI/AAAAAAAAA3Q/viQxwQtbNd0/s400/S4012396.JPG

Knowing that I would have to replace the driveshaft eventually, I went on and bought a dual cardan driveshaft. Because it wouldn't fit with the slip yoke (too long), I just put it on the shelf for a rainy day and hoped I wouldn't have to call upon it.

After the driveshaft played twister with itself :cry: , it was either time to get the driveshaft shortened or bite the bullet and get hooked up with a Slip Yoke Eliminator kit.

I decided that the SYE (slimanator-as my wife says) would be the better route to go, so I purchased the Teraflex 231 HD SS from DC4WD.COM (http://www.dc4wd.com).

<<PERSONAL EDIT>>

I figured I'd post some pics of the process and let you guys see what I did this weekend :-)



Transfer Case Before

http://lh4.google.com/bizron/Rw5IKc_wGEI/AAAAAAAACXs/x6FsI8s0dgk/s400/S4013687.JPG


Empty Case

http://lh6.google.com/bizron/Rw5Ia8_wGNI/AAAAAAAACY0/pSgrUTtjfB0/s400/S4013696.JPG


the shift fork had to be shortened for clearance reasons

http://lh5.google.com/bizron/Rw5Ifs_wGQI/AAAAAAAACZM/ajynjhqcJ5w/s400/S4013699.JPG


Back together in the case

http://lh4.google.com/bizron/Rw5Ijc_wGSI/AAAAAAAACZc/YhGmMiRAeu0/s400/S4013701.JPG


Completed SYE

http://lh6.google.com/bizron/RxO5Js_wGjI/AAAAAAAACcY/zTvCYsmtFZI/s400/S4013748.JPG

http://lh4.google.com/bizron/RxO5FM_wGhI/AAAAAAAACcI/Zjc5DIby104/s400/S4013746.JPG


new drive shaft to be installed

http://lh3.google.com/bizron/RxO5R8_wGlI/AAAAAAAACcs/Nnra_QdMZ5M/s400/S4013750.JPG


I've went through the gearing and made sure all the modes work (2H, 4H and 4L) so now its time to put everything back together. I never had any crazy vibrations after my SOA, but at least now I've got good stuff delivering the power :P . Eventually stuff has to stop breaking haha.

Thanks for looking!

:grin:

[Hokie_YJ]

How hard was it to do it with the case still in. I pulled mine to do my SYE, if I had a lift I probably woulda left it in though.

[Bluegill]

Nice work Byron! It's great not worrying about vibrations & feeling confident in the rear shaft. :wink: BTW, your wait ordeal was Teraflex's fault, I never realized their service was so poor until dealing with them recently.

Ben, my TJ only had a 2" pad lift when I installed my 231ESS with the case still in the Jeep. Piece of cake! :grin:

[bizron]

Leaving the tc in for the swap didn't make it too difficult. If you have some strength in your arms, you should be fine :wink:

BY FAR the worst part about the whole thing has been the snap rings. I'm confident that my project took twice as long because i tried to use non-professional grade pliars.

[Hokie_YJ]

BY FAR the worst part about the whole thing has been the snap rings. I'm confident that my project took twice as long because i tried to use non-professional grade pliars.

Did you use snap-ring pliers, or lock-ring pliers. There's a difference, and the 231 uses lock rings instead of snap rings. I bought a set of lock ring pliers from Sears and mine came off pretty easily.

[Hadfield4WD]

BY FAR the worst part about the whole thing has been the snap rings. I'm confident that my project took twice as long because i tried to use non-professional grade pliars.

Did you use snap-ring pliers, or lock-ring pliers. There's a difference, and the 231 uses lock rings instead of snap rings. I bought a set of lock ring pliers from Sears and mine came off pretty easily.

The 231 uses lock rings, but the kit I bought came with snap rings so you need both. I also have the teraflex.

I took mine out and and decided next time I would leave it in. I dropped it on my head as I pulled it off the output of the transmission. I figured it would be hard to pull, because of some sort of seal. I got into position and jerked hard and it came right out and knocked me out. My buddy was watching the whole thing and after he finished laughing he got a cup of ice water and woke me up.

[SamuraiGuyTN]

thats pretty funny right there. I think I would have died laughing. Glad you didn't ask me to come over. :lol: Glad your not hurt though

[Hadfield4WD]

thats pretty funny right there. I think I would have died laughing. Glad you didn't ask me to come over. :lol: Glad your not hurt though

This kind of thing just happens to me. Everybody I told said it was funny as they looked at the lump on my forehead the size of a golf ball. I'm alway good for some comic relief.

By the way I like that twisted drive shaft.

[bizron]

you should see it now hahaha maybe I'll take pics

[Jeep07]

Glad to see the rig back together now. I have a replacement xj shaft for the front. We just need to adjust the lenght and put new ujoints in it.

[bizron]

Here are some pics of the pretzel driveshaft

http://lh6.google.com/bizron/Rxqya8_wG5I/AAAAAAAACfo/QAumM1T3SJQ/s800/S4013773.JPG

http://lh4.google.com/bizron/RxqyYc_wG4I/AAAAAAAACfg/_T4MYD7oEoM/s800/S4013771.JPG


Here are some pics of the final product

My rear pinion angle looks good.

http://lh4.google.com/bizron/RxqyRc_wGzI/AAAAAAAACe4/tArKns_QXjg/s800/S4013766.JPG

http://lh4.google.com/bizron/RxqyPc_wGyI/AAAAAAAACew/S21rfxvdf6g/s800/S4013765.JPG



Completed install with everything bolted back up

http://lh5.google.com/bizron/RxqyTs_wG0I/AAAAAAAACfA/fAmd7WlawQI/s800/S4013767.JPG

http://lh5.google.com/bizron/RxqyNs_wGxI/AAAAAAAACeo/X9x5Fu1nS00/s800/S4013764.JPG


I haven't had a chance to drive it yet, but I think it'll be great.


:grin:

[Bluegill]

You'll definitely notice the difference. :wink:

[bizron]

Something that I've been meaning to do for a long time was to clean up the electrical wires under my dash.
When I first got the jeep, I knew that I'd have to eventually go through all of this mess and figure out where all those random wires were going. Everything was so spliced and diced that I could just imagine all of it catching on fire one day.

Here's a picture of what the mess looked like when I took off the wire ties.

BEFORE:

http://lh3.google.com/bizron/RxO5T8_wGmI/AAAAAAAACc0/Lr0Drn7GRHs/s800/S4013751.JPG


I kept putting off the work because I knew it wasn't going to be fun going through the hayne's manual reviewing all the schematics.
Well....I finally bit the bullet and decided to clean it up. I'm really glad I did because it was considerably easier than I was expecting.


The rat's nest of wires wasn't actually important because.....



it was actually an old car alarm!

I'm sure it was a spiffy unit back in this jeep's "prime", but now it was just an awful mess.

You can see how much junk I was able to remove from under the dash.

http://lh4.google.com/bizron/RyUsBVz5zrI/AAAAAAAACjY/raGsnEbsr9M/s800/S4013815.JPG


With all that garbage cleaned out and everything fixed right...this is how she looks now :-)


AFTER:

Alarm and wires removed, splices fixed, and wires tucked and tied back where they belong.

http://lh3.google.com/bizron/RyUr5Fz5znI/AAAAAAAACi4/3QFw_fYlFUY/s800/S4013811.JPG


Definitely a huge improvement in the looks and probably the safety department as well.

the new view from the wheel.....

http://lh4.google.com/bizron/RyUsLVz5zwI/AAAAAAAACkA/QUHlPlasja0/s800/S4013820.JPG

Thanks for looking!

[Hokie_YJ]

Very nice! Mine could use a little bit of that...


























wanna do it for me? :lol:

[Jeep07]

Looks alot better.

[Frequency]

Very nice Bizron!! Awesome Job :shock: :smokin:

[bizron]

wanna do it for me? :lol:


When my spine heals from doing the limbo under my steering wheel while simultaneously having my hands shoved up under the dash, I will probably still say no hahaha :blob2: :blob3: :blob4: :blob5:

[bizron]

Here's the latest mod to my jeep :-)

HuskyLiners floor mats hahaha

http://lh5.google.com/bizron/R3CQvVgj1rI/AAAAAAAACq4/TxGJ0JIbI9s/s800/S4013985.JPG


http://lh3.google.com/bizron/R3CQ01gj1uI/AAAAAAAACrU/3df8RSYF_mg/s800/S4013988.JPG

These floormats are awesome because they fit the contours of the floor boards like a glove!

http://lh5.google.com/bizron/R3CQ4Vgj1wI/AAAAAAAACrk/lVilSXMS9fk/s800/S4013990.JPG

Thanks natron for the Christmas present!

[Jeep07]

looks good. :grin: making it to nice to sell :wink:

[Jeepguy16]

that driveshaft looks familar, im glad the length was correct for what you were doing looks good. :grin:

[Dino1967]

nice :!:

[bizron]

that driveshaft looks familar, im glad the length was correct for what you were doing looks good. :grin:

Yeah, it worked out nicely :grin:

[Want2Wheel]

Get it muddy, and have fun.

[bizron]

i need to update this thread...its been a while since I've reported progress :-)

[bizron]

I haven't updated the build thread in quite some time, but I figured late was better than never. The following is a summary of things that have been done either as improvements to the jeep or fixing things that broke. Enjoy!

Added some KC Daylighter off-road lights
http://lh6.ggpht.com/_BJMrv-Rx5Lw/SALKGTk-83I/AAAAAAAADIs/HaCnRpja804/s400/S4014586.JPG

daylighters off
http://lh6.ggpht.com/_BJMrv-Rx5Lw/SALKOTk-8_I/AAAAAAAADJs/WAkUau_PIJg/s400/S4014594.JPG

daylighters on
http://lh3.ggpht.com/_BJMrv-Rx5Lw/SALKNjk-8-I/AAAAAAAADJk/1-4AWxZxCl4/s400/S4014593.JPG

bought a used soft-top and installed it
http://lh3.ggpht.com/_BJMrv-Rx5Lw/SPA-J5X3P2I/AAAAAAAAEUo/vioir9gvk9Y/s400/S4015231.JPG

Installed a small amp for tunes
http://lh5.ggpht.com/_BJMrv-Rx5Lw/R_l6OUcqtPI/AAAAAAAADBM/OGSIpD3T89c/s400/S4014507.JPG

http://lh5.ggpht.com/_BJMrv-Rx5Lw/R_l6BUcqtGI/AAAAAAAADAA/91gWv_KcFeo/s400/S4014498.JPG

passenger
http://lh6.ggpht.com/_BJMrv-Rx5Lw/R_l6LkcqtNI/AAAAAAAADA4/20BY4mz-oNI/s400/S4014505.JPG

driver
http://lh4.ggpht.com/_BJMrv-Rx5Lw/R_l6NEcqtOI/AAAAAAAADBA/nR3u0wd3Wzg/s400/S4014506.JPG

New battery connections and terminals
http://lh6.ggpht.com/_BJMrv-Rx5Lw/R_l55kcqtCI/AAAAAAAAC_g/BBM-t-GtHbk/s400/S4014494.JPG

installed new switch panel (lexan painted black) and cb
switches control the daylighters and the power to the amp
http://lh5.ggpht.com/_BJMrv-Rx5Lw/SALK0Dk-9VI/AAAAAAAADMg/qkSV16PgMDo/s400/S4014616.JPG

http://lh4.ggpht.com/_BJMrv-Rx5Lw/SA1jVpr0vtI/AAAAAAAADS0/R6EUqSqwKJo/s400/S4014656.JPG

installed 4 new u-joints

replaced the clutch master cylinder


replaced the clutch slave cylinder
http://lh5.ggpht.com/_BJMrv-Rx5Lw/SPA-He3_7JI/AAAAAAAAEUI/u-KVzBRvj68/s400/S4015227.JPG

installed a new clutch and pressure plate
http://lh5.ggpht.com/_BJMrv-Rx5Lw/SO2MYnXFGSI/AAAAAAAAES4/_i5Zolo_Hxc/s400/S4015220.JPG

http://lh5.ggpht.com/_BJMrv-Rx5Lw/SO2MRl01d_I/AAAAAAAAERo/eC3Y_-1suL4/s400/S4015210.JPG

post-battle with the pilot bearing
http://lh3.ggpht.com/_BJMrv-Rx5Lw/SO2MI-6aE9I/AAAAAAAAEQQ/YoSCJBEjJTU/s400/S4015199.JPG

On an outing, my throttle cable broke...so I had to install a new one from quadratec. Crafty use of a zip tie allowed me to get back home.


coming soon...
New traction bar to help with that pesky spring wrap
http://lh6.ggpht.com/_BJMrv-Rx5Lw/SRG4Vq7G0oI/AAAAAAAAF4w/ESkwtwx4p-s/s400/IMAGE_292_small.JPG

Install new - shorter - rear shocks vertically and install new traction bar. Whenever Wesley has some time to break out the welder for me :icon_smile:.

havin' fun after work one day
http://lh4.ggpht.com/_BJMrv-Rx5Lw/SA-VMJr0v3I/AAAAAAAADUc/RUApZxkti8Y/s400/DSCF5621.JPG