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]
________________________________________

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 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 - 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.