My build - Expedition Rig - 2003 WJ 4.7 HO - Page 3 - JeepForum.com
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post #31 of 1665 Old 06-30-2008, 04:59 PM Thread Starter
theksmith
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Originally Posted by TX-WJ View Post
Looking swaeeet so far

Now slap a rear addco HD sway bar, best $200.00 spent on any mod.

Edit: Oh yeah, don't forget the energy greasable bushings.
thanks! i had thought about and addco becuase it is a daily driver and i would like more stability, but how much does it end up limiting your flex off-road?

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post #32 of 1665 Old 06-30-2008, 05:09 PM
TX-WJ
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thanks! i had thought about and addco becuase it is a daily driver and i would like more stability, but how much does it end up limiting your flex off-road?
It sure limits your flex, but the onroad handling is SOOOO much better I do not regret it. I have been thinking of a way of disconnecting the rear sway when offroad, but have not come around to doing it yet, I'm sure there's a way; the alternative is simply slapping the stocker for a planned wheeling trip.
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post #33 of 1665 Old 06-30-2008, 06:15 PM
MDZJ88
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Nice Rig! This is what I plan to do with my next ZJ (that I just got today)! Xxxpedition.com is an awesome site/blog BTW, though I'm sure you've probably seen it!
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post #34 of 1665 Old 06-30-2008, 06:42 PM Thread Starter
theksmith
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Originally Posted by MDZJ88 View Post
Nice Rig! This is what I plan to do with my next ZJ (that I just got today)! Xxxpedition.com is an awesome site/blog BTW, though I'm sure you've probably seen it!
somehow i've never run across that before, thanks for the link!!
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post #35 of 1665 Old 06-30-2008, 06:46 PM Thread Starter
theksmith
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Originally Posted by TX-WJ View Post
It sure limits your flex, but the onroad handling is SOOOO much better I do not regret it. I have been thinking of a way of disconnecting the rear sway when offroad, but have not come around to doing it yet, I'm sure there's a way; the alternative is simply slapping the stocker for a planned wheeling trip.
if i ever end up doing the mod where you cut-out the spare tire well and then raise the tank, then i think it would free up enough room that you could move to a sway bar mounted up at the frame instead of axle (maybe from an XJ or TJ). then fab up link mounts on the axle, and use standard jks disconnects. at this point you could disconnect and support the bar/links at the frame the same way the front does... one of those ideas that i'll probably never get around to actually trying!
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post #36 of 1665 Old 06-30-2008, 06:52 PM
Shelbyzz
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any pictures?
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post #37 of 1665 Old 06-30-2008, 06:56 PM Thread Starter
theksmith
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any pictures?
of what ?
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post #38 of 1665 Old 06-30-2008, 07:16 PM
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i'll let you know after i've had them offroad and for more than a few days!

the seem LOUD... i don't think any louder than any other MT, probably actually better than many, but i have always only had AT's (nitto tera-graplers'), so i'm used to quiet! but farkit, they look sweeeeeet!
The KM2s are great. I am running them too. They are A LOT quieter than my old Trxus MTs. I haven't really wheeled on them yet to comment on their performance off-road but I suspect they will be sweet on the rocks!
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post #39 of 1665 Old 07-01-2008, 09:00 AM
Coletrickle
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Crazy rig! Nice work.

93 Grand Wagoneer
5.5" Hybrid Lift/BDS CA's
231/skids/33" KM2's
Homegrown Bumper
Aussie
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post #40 of 1665 Old 07-01-2008, 07:50 PM
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thanks! i had thought about and addco becuase it is a daily driver and i would like more stability, but how much does it end up limiting your flex off-road?
they do limit flex but IMO they work as good as bump stops... I have had no real issues with the flex but I have them front and rear and love what they do for the handling!!

2004 Overland 4" KOR/IRO Long Arms
2004 Rubicon 6.5" RK X-Factor LA on 35" KM2s 488s Tom Woods & plenty of BTF Armor ORO U-Turn system
1995 Jeep Orvis 4.0 3" Rancho
www.jeeporvis.com ... www.jeepartist.com ... www.kmaoffroad.org Virginia Beach ... www.obxbreakers.comOff season Jeeper Deals
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post #41 of 1665 Old 07-02-2008, 11:49 PM Thread Starter
theksmith
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trans mount bolts with clayton crossmember issues

while under the jeep i noticed that the bolt heads for the bolts holding the trans mount to the crossmember hung down - and that just didn't seem right.

i took one out and sure enough, you could see how clayton designed the crossmember for the bolts to recess inside the crossmember, but apparently the bolts on my year had larger attached washers than were expected. the shop that did my clayton install should have noticed this as the washers were caving into the crossmember holes and if you tightened the bolts, the more they just caved into the holes.

here's a pic of how it was (one bolt removed already):


and here's a pic showing the OEM bolt on the right, and the ones I replaced them with on the left:


this fixed a slight CLUNK i had when going from acceleration to coast and vise versa.
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post #42 of 1665 Old 07-03-2008, 07:52 AM
ArloGuthroJeep
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Wow, sketchy job that shop did. Especially since the Claytons kit comes with new bolts for the crossmember.

'04 WJ, 6" Clayton LA's, 242 SYE, 35" BFG MT KM2's, 4.56 gears, & D44a locked
'14 WK2 Limited w/5.7L, ORAI, & Tow Package
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post #43 of 1665 Old 07-03-2008, 08:42 AM
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Quote:
Originally Posted by theksmith View Post
if i ever end up doing the mod where you cut-out the spare tire well and then raise the tank, then i think it would free up enough room that you could move to a sway bar mounted up at the frame instead of axle (maybe from an XJ or TJ). then fab up link mounts on the axle, and use standard jks disconnects. at this point you could disconnect and support the bar/links at the frame the same way the front does... one of those ideas that i'll probably never get around to actually trying!

the gas tank mod is not hard at all. i am still trying to figure out the sealing up issue with a better more semi permenant solution.

The easy solution is to take just one side of the sway bar loose. I unhook the rear passanger lower side and its like there is no rear sway bar at all. it takes me 2 sec at the trail head.

-Jeb
99 WJ 4.7V8 selc-trac swap
285s re-tread
IRO 6.5 Long Arms
Aussie Locked Rear

in the works... lots deployments are great for jeep budgets

Go Doorless!


Things i need..
good spots in the mid atlantic to camp, hike, fish, kyak and wheel, if you know please share

Quote:
Originally Posted by 5.9 ANDY
i would do the rear.
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post #44 of 1665 Old 07-03-2008, 10:37 AM Thread Starter
theksmith
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the gas tank mod is not hard at all. i am still trying to figure out the sealing up issue with a better more semi permenant solution.
do you know of any good writeup's for the gas-tank lift? i saw one over on mallcrawlin, but the main thing it didn't address is my biggest question... how do you re-route the filler tube and breather? it looks like you have to notch and re-weld the frame rails? thanks
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post #45 of 1665 Old 07-03-2008, 07:17 PM
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Originally Posted by theksmith View Post
do you know of any good writeup's for the gas-tank lift? i saw one over on mallcrawlin, but the main thing it didn't address is my biggest question... how do you re-route the filler tube and breather? it looks like you have to notch and re-weld the frame rails? thanks
I don't have a writeup, but a 3" hole saw (or plasma cutter) through the frame rail did the trick for me. Then, find an appropriately sized length and diameter of exhaust tubing, insert it and weld in place. Run the filler and breather tube through the new sleeve.

86 CJ7: Chevy 350, Th 350, SOA on 33's
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