Gary B's Buildup Thread (YJ)

[OverlandZJ]

Introducing my son's new to him 94 YJ. His current Jeep fried the wiring harness and while replacing we found other issues which prompted a replacement platform.

We looked for several months for a rustfree YJ in good condition with a 4.0L,manual and AC. After posting wanted ad's on most forums i knew of we finally found this in South Carolina.

It's a 94 Wrangler YJ with the options he just had to have. We are transplanting his older mods from his other YJ and adding a few new ones.

So far he has replaced the factory grey carpet with his black bestop carpeting, his aftermarket console and 6 speaker soundbar.

Today i pulled his NP231 transfer case with Tom Woods SYE and shaft, tomorrow i will be swapping the input gear from a 21 to 23 spline input. This will be used in the new YJ.

Other parts/accessories awaiting install are:

BDS 3.5" lift
Ford 8.8 rear axle with disc brakes,1" spacers and 4:10's.
Front Dana30 with matching ratio,fully rebuilt.
PosiLock cable actuator
His stereo system
32" BFG MT's on factory Jeep 5 spoke alloys.
ARB Safari Snorkel with K&N
Warrior rear cargo rack
Warn M6000lb winch
Hella 550 and Hella 500 lights
CB with weatherband
RE hand throttle
TFX exhaust and highflow cat


Future mods to include:

ARB for 8.8
F&R Bumpers
Front cage
Borla Header
Power invertor
And more to come...


Here's a pic of the vehicle as purchased, i'll update thread with photo's over the next few weeks as we rebuild it.

[LUISJG]

looks like you gonna be very ocupied this winter. :)

[articulate]

looks like you gonna be very ocupied this winter. :)
Agreed.

Very cool, John and Gary. I see that you boys want to put in a power inverter and winch. Any considerations for a double battery system? I love how you have a Ford 8.8 merely sitting in the garage awaiting install. :)

Have you guys thought about a shackle reversal, too? That would be a really neat addition on the front end.

[OverlandZJ]

Agreed.

Very cool, John and Gary. I see that you boys want to put in a power inverter and winch. Any considerations for a double battery system? I love how you have a Ford 8.8 merely sitting in the garage awaiting install. :)

Have you guys thought about a shackle reversal, too? That would be a really neat addition on the front end.


Dual batteries are a good idea, that'll have to be added.

Is a shackle reversal system (SRS) a big improvement on road? Most of the mileage will be asphalt and two track with an occasional trail thrown in. I understand most if not all systems add height to the vehicle?

This Jeep will go together faster than y'all think....he's currently driving my Jeep! :ylsmoke:

[articulate]

Good question about the SRS. I don't know. I thought that with the insane axle, winch, 3.5" BDS that you guys were shooting for a killer rock-trail machine. A shackle reversal would be a cool thing for that kind of a Jeep. But in this case? Maybe not. I'm really not very familiar with them. I've committed myself to helping a friend with a YJ install one, but that won't be until this Spring.

This busted my gut! Can't stop laughing!

This Jeep will go together faster than y'all think....he's currently driving my Jeep!

[OverlandZJ]

I see how i gave you that impression...but it wont be on the rocks much. He's young and wanted a taller lift so...

I actually found the 8.8 with all the required bracketry installed along with a matching ratio front axle for cheaper than i could have regeared his stock axles. Definately got lucky there.

Were going to shy away from the SRS now and concentrate on some of the other mods he wants.

I have the transfer case input gear swap almost done, found i needed new shift fork pads. Awaiting them, ordered an extra couple sets to keep in the cabinet for future.

[david despain]

I have the transfer case input gear swap almost done, found i needed new shift fork pads. Awaiting them, ordered an extra couple sets to keep in the cabinet for future.


hahahahaha... my wife always laughs at me and makes fun of me when ever i say" yeah i think i have that in stock" or "on the shelf in the garage" she just doesnt understand why i have shelves that look like a parts store and why i need to keep spares on hand. :D good on ya!

[OverlandZJ]

David, i'm the same way. I'd rather not run out to the parts store in the middle of a job or have to stop for the night because i didnt think ahead.

OK, after a week on the "honey do list" were back on the swap. Gary is off today and we started the suspension and axle swap. Thank God for decent weather...wish i had a garage.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/HPIM2560.jpg

[cshontz]

That's a great looking YJ!

:lurk:

[articulate]

http://i32.photobucket.com/albums/d24/ExpeditionXJ/HPIM2560.jpg
:xxrotflma

If it helps, I wish you had a garage too.

And, uh, nice Christmas lights. I still haven't put any up. :)

[86cj]

What a cool project with your son..good times.....We had real cold weather but have been in the 50's lately also, good luck cold is coming.

That is a nice set up, those springs are a hot set up for CJ guys looking for some flex and ride comfort. A good Jeep to cut your teeth on for sure. I had to fix almost everthing (really) on my CJ what a POS and learned alot. I love it and will keep it. Every Jeeper should start with a AMC SWB and leaf springs. Then you will appreciate the reliability and ride comfort Jeep offers today.

[Gary B]

ok guys, heres whats done so far...

Rear springs are installed along with the ford 8.8. Its sitting real nice in the rear with the 32" BFG MT'S

Noticed the clutch grabs real low, might as well replace while the transfer case is out. Looking into a Center Force II.

Mom has had Dad and I busy painting and doing other chores around the house, this should beroad ready around new years. :smiley_drive: :camping:




http://i32.photobucket.com/albums/d24/ExpeditionXJ/HPIM2563.jpg

[OverlandZJ]

Making progress, lift and axle swap are completed. Rain has been an issue the last two days, would have liked to get a bit more done.

I received the shift fork pads for the transfer case only to find the shift fork itself worn when i attempted to reassemble. How i missed this i'll never know. Fortunately i had another transfer case for parts under the workbench and grabbed the fork from it. We should have it ready for assembly this weekend.

As it sits now..

http://i32.photobucket.com/albums/d24/ExpeditionXJ/HPIM2584.jpg

[OverlandZJ]

Sorry about the lack of updates, my old laptop (6 months old) took a dump and took all my pics with it. :mixed-smiley-030:

Gary has been driving it and the shed still has plenty of parts to install.

Spring is around the corner and we'll get back to building this.

:suning:

[91xlt]

Good to see you keepin' it in the family!:beer:

[YJ Dave]

Any updates?

[OverlandZJ]

Any updates?

Making progress much slower than anticipated, Gary is pretty much working 7 days a week and most time is dedicated to maintenance. We installed new ball joints,rotors,pads,TPS and 02sensor, speedo gear.

Posi-Lock is installed, add-a-trunk, MORE 5/8" lift rear boomerrang shackles are installed to clear Military wrap springs from frame. CB, Altimeter,we had to replace a BDS leafspring under warranty as the main leaf twisted (BDS was quick with this).

We bought a new Header from APN and will be installed with the new high flow catalytic convertor and TFX cat back sysyem. New CenterForce clutch is awaiting install when we do the exhaust.

Snorkel install hopefully this week. And i got the XMAS lights down... :clapsmile

Need to get a winch tray for the Warn winch.

http://i32.photobucket.com/albums/d24/ExpeditionXJ/006.jpg