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Building a Bumper?Ruffstuff Axle Simple Swap Kit!~Artec JK 1 TON SWAP~

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Unread 02-18-2012, 04:43 PM   #61
gtg413i
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Now time to prep the ZJ bottle. Here is a pic of the ZJ and WJ bottle beside eachother. For the ZJ bottle, unscrew both pumps. For the WJ bottle, pull out each pump. Clean the black filter on the WJ pump (saw a bunch of slime in mine in the 2nd pic below) and then press each WJ pump snugly into the the bottom of the ZJ pump (put the white pump in the back and the black pump in the front under where the filler opening is).

pump-differences.jpg   img-20120218-00211.jpg  
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Unread 02-18-2012, 04:44 PM   #62
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No trim the tabs on the ZJ pump to look like the pictures below.
cut-washer-long-plastic.jpg   cut-washer-part-2.jpg   cut-washer-part-3.jpg  
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Unread 02-18-2012, 04:45 PM   #63
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The yellow box is where the new bottle will fit snugly. The thing circled has to be moved closer to the bumper, so unscrew the 2 10mm screws holding it on.
before-install-engine-bay.jpg  
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Unread 02-18-2012, 04:49 PM   #64
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Now, trim this hard plastic off around the wires to give more space below the bottle for the pumps. Cut all of the hard plastic that sticks up ninety degrees. Snips or dremmel work. Careful not to cut into any wires. Since there are water connectors above, you may want to cover these wires with something like electrical tape. I didn't.
img-20120218-00208.jpg  
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Unread 02-18-2012, 04:51 PM   #65
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Now, relocate the pump connectors and tubing. You'll need to free the wiring from the loom like in the picture below.
separating-wires.jpg  
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Unread 02-18-2012, 04:54 PM   #66
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Now test fit your bottle until you get it right. When it is right, drill two holes for screws. Try to get the bottle below the level of where the hood closes. You can do it, but it will be tight. Then install the connectors, tubing, and 2 screws. I did not have a 3rd hole for the level sensor so left it out. This won't bother me as I don't care about a warning for low washer fluid. Without the sensor, you don't get any codes or warning, so I zip tied the original sensor connector away.
cables-relocated.jpg   screw-locations.jpg  
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Unread 02-18-2012, 04:54 PM   #67
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Reattach that thing we moved forward earlier. I just zip tied mine to the bottle.
zip-tied-relocate-valve.jpg  
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Unread 02-18-2012, 04:56 PM   #68
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Add washer fluid, test system and enjoy. Note - I did experience less flow to my front washer - I think I pinched a hose underneath, but it's not too bad. Also, you will hear the pumps are very loud now that they are close to you (you could barely hear them before).
final-product..jpg  
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Unread 02-18-2012, 05:57 PM   #69
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Good job on the write ups
I always get in to big a hurry so I always forget to take pics
Good looking jeep man, keep up the good work.
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Unread 02-18-2012, 07:03 PM   #70
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Awesome writeup! I wanna do this sooooo bad but no one wants to give me a deal to Hawaii...
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Unread 02-26-2012, 05:17 PM   #71
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Did fluids to transfer case, front and rear differential, added solid dana 30 diff cover and lubelocker gasket. Changed the oil (mobile1 10w30) and put on my wheel spacers (1.5" rough country from jf member). I rub in at full reverse left turn on front of front tires- trimmed a litte off inside of bumper and no more rubbing- now off to the desert to wheel.
solid-d30-cover.jpg   spacers-before.jpg   spacer-after-4.jpg   spacers-after-3.jpg  
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Unread 03-11-2012, 08:58 PM   #72
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Quote:
Originally Posted by gtg413i View Post
More pics.
That bottom picture is exactly what I want my jeep to look like, the height and stance is perfect.

Edit: the picks didn't copy, I like the look with the 3" IRO kit and the 265/65/17s. I'll be doing the same thing except I'll keep my stock wheels.
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Unread 03-16-2012, 10:29 AM   #73
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Hey bud thanks for the washer bottle write up! going to do this soon
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Unread 03-31-2012, 06:36 PM   #74
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Follow-up on the diff fluid change. I would not do the royal purple and molar friction modifier. Because the royal purple already has friction modifier, adding more means the LSD doesn't work as efficiently. So.. Use royal purple and if you hear the diff chattering when turning, add a little friction modifier at a time until it stops chattering. Or add the diff fluid with no friction modifier and the recommended amount from Chrysler- you'll need three of the small bottles all together total for front and rear.
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Unread 03-31-2012, 06:40 PM   #75
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Quote:
Originally Posted by thisguyhasadd2 View Post
Hey bud thanks for the washer bottle write up! going to do this soon
Hope it helps or inspires- alwayshi, have you done yours yet? There are already good write ups I based my install on, but they weren't as detailed, so hoping this pushes people over the edge to buy the $20 zj bottle and tackle this easy, satisfactory mod.
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