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Unread 01-01-2011, 12:32 PM   #1
Fawkes
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Pelé: EfEmDee's Build Thread

So I did the introductions thing, I've posted my full profile, a couple of photos in the gallery (I really need to get a paid membership so I can do more there), chimed in a few places in the WJ forums, read a LOT (thanks you all for contributing your collective knowledge), and even made a few purchases off of fellow jeepforum members.

It's a new year, and when I'm all done with my WJ (Pelé), I should have an (almost) new Jeep. Time for a build thread!

Background on the Jeep:

Pelé's name came about because this WJ was originally my wife's “soccer mom SUV”. It's a black 2000 Laredo. It's not hard to figure out from there.

I purchased the vehicle off-lease at the end of 2004, with ~48k miles on it. It's currently at 213k and climbing. The Jeep rarely saw anything off-road until this fall, and has spent most of its hours and miles purring along at 70MPH and 2000 RPM. For the first 4 years we had it, this WJ was my wife's DD and dog hauler, with frequent (2x/year) cross-country road trips to NY,NJ and VA. When she wanted a new vehicle at the end of 2008, we traded in my 99 Durango on her Subaru Impreza, and I inherited Pelé.

For the last two years, it's served as an inclement-weather backup (my DD is a clapped-out 99 Toyota Corolla that gets 34+ MPG), hunting vehicle (trails and farm fields mostly), tow vehicle for the duck boat, and occasionally its intended purpose as a ladder/tool/employee hauler (it's technically a business vehicle).

So with Pelé starting to show his age, the economy being what it is (can't really afford to drop the coin on a new/newer used truck), our first kid due in a month, the need to spend some business money (taxes are the debil ), and the utmost faith in the 4.0 I6; we made the decision to give Pelé some lovin', make some upgrades, and (hopefully) get another 100k without a major engine overhaul. The goal is to have a fairly mannered DD that is capable in the snow, safe for the baby, useable as a work truck, and is worry free as an occasional off-road/hunting/toy hauler.

For those of you who are members of Arfcom (I know you're out there ), SHTF/Bug-home capability is also a big plus.

So without further ado, here's Pelé's specs, the upgrades that are happening shortly, and some vanilla future plans...

Before:


Pelé's Build Sheet


*H7 Cloth Low-Back Bucket Seats
-AZ Agate
ADBP Protection Group
ADC Convenience Group
AHT Trailer Tow Group
APAS Monotone Paint
ARNS Laredo Decor Group
AWSS Smoker's Group
A24P 4.0L Engine(ERH)/4Spd Auto Trans(DGK
BAZS 136 Amp Alternator
BC6S 625 Amp Maintenance Free Battery
BRYS Anti-Lock 4-Wheel Disc Brakes
CACS Low Back Bucket Seats
CBWS Highline Door Trim Panel
CFNS Rear 60/40 Folding Seat
CGWS Next Generation Front Air Bags**
CKDS Floor Carpet
CKNS Cargo Compartment Carpet
CKRP Cargo Net
CKTS Cargo Tie Down Loops
CLEP Front & Rear Floor Mats
CLPS Door Sill Scuff Pads
CSCP Cargo Compartment Cover
CSRS Passenger Assist Handles
CUDS Mini Overhead Console
CUFS Full Length Floor Console
DGB All 4-Speed Automatic Transmissions
DGKS 4-Spd. Automatic 42RE Transmission
DHAS Lock-Up Torque Converter
DHPS Selec-Trac Full Time 4WD System
DJJS Dana 30/186MM Front Axle
DMEP 3.73 Rear Axle Ratio
DRMS Dana 35C/194MM Rear Axle
EAAC All Engines
ERH 4.0L I6 Power Tech Engine
GBBS Tinted Windshield Glass
GCBS Front Door Tinted Glass
GEGS Deep Tint Sunscreen Glass
GEPS Flipper Liftgate Glass
GFAS Rear Window Defroster
GNAS Rear View Day/Night Mirror
GNVS Sun Visors w/Vanity Mirror
GTM Power Heated Mirrors
GXMP Remote Keyless Entry
GXXS Sentry Key Theft Deterrent System
HAAS Air Conditioning
HGAS Hood Insulation
HGDS Deluxe Insulation Group
JAYS Instrument Cluster w/Tach
JCBS 120 MPH Primary Speedometer
JHAS Var Intermittent Windshield Wipers
JHBS Rear Window Wiper/Washer
JJAP Cigar Lighter
JJBS Dual Note Electric Horns
JKAS Locking Glove Box
JKPS 12V Auxiliary Power Outlet
JKYS Power Accessory Delay
JPBS Power Locks
JPDS Power Windows, Driver One-Touch
K4AS STRIPE/BADGE/MOLDING/COLOR
K5AS STRIPE/BADGE/MOLDING/COLOR
LACS Illuminated Entry
LAGS Warning Chime
LAZP Vehicle Information Center
LBBS Courtesy Lamps
LBCS Glove Box Lamp
LBDS Ash Tray Lamp
LCES Rear Courtesy/Reading Lamps
LDAS Underhood Lamp
LDBS Cargo Compartment Lamp
LETP Traveler/Mini Trip Computer
LMBS Halogen Headlamps
LNJ Fog Lamps
LPSS CHMSL Lamp
MDAP Front License Plate Bracket
MFZS Bright Grille
MHAS Black Windshield Moldings
MVBS Grand Cherokee Badge
MVCS Jeep Badge
MVDS 4X4 Badge
MWGS Roof Rack
NAA Federal Emissions
NFPS 20.5 Gallon Fuel Tank
NHMS Speed Control
PX8 Black Clear Coat
QX8S Black Clear Coat
RAAC All Radio Equipped Vehicles
RAZ AM/FM Cassette Compact Disc Radio
RCGS 6 Speakers
RDDS Fixed Long Mast Antenna
SBAS Power Rack and Pinion Steering
SCAS Steering Wheel
SDAS Normal Duty Suspension
SUAS Tilt Steering Column
TBLS Inside Mounted Spare Tire
TBW Full Size Spare Tire w/Matching Whl
TR7P P225/75R16 OWL All Season Tires
TZAS Goodyear Brand Tires
WDSS 16X7.0 Forged Aluminum Wheels
WLZC All Aluminum Wheels
XPFS Protective Coating and Remover
YAAS Build To U.S. Mkt. Specifications
ZKFP Spring - Left Front
ZKYP Spring - Left Rear
ZYFP Spring - Right Front
ZYYP Spring - Right Rear

Our records indicate that the following recall campaign has not been
performed by an authorized dealer:

882 REPROGRAM PCM OBD READINESS CODES

We suggest that you contact your local authorized Chrysler, Dodge, Jeep?
or Ram dealer to make arrangements for an inspection and, if necessary,
corrective action at no charge to you

Installed items/upgrades

Yakima low-pro roof bars
Jotto desk laptop mount (I've been running a full-screen GPS from the laptop on long hauls in one vehicle or another since 2001)
Current tires are 235/75-16 Kelly Safari SUV (will never, ever buy again)

Repairs made


Water pump
Mechanical fan clutch

Planned upgrades

Yellow: Parts awaiting install.
Red: Parts in transit.
Blue: Complete.
Silver: Decided against/deleted.

Suspension/Tires:
3.5” Rocky Road Outfitters “Trailblazer” kit:
Old Man Emu +1.5” springs
+2” RRO urethane spacers
RRO Lower control arms
RRO Adjustable track bar
RRO 1”
transfer case & A-arm drop spacers
RRO shock absorbers with black boots


Iron Rock Offroad dual steering stabilizer kit:
Tenneco/Monroe stabilizers with black boots.

Zone front and rear extended swaybar endlinks (non disco, want to paint black)
Zone 2" rear bumpstop extensions

FMD fabbed 2" front bumpstop extensions
Addco 1” rear swaybar
Energy greasable swaybar bushings


Black Rock Series 997 (Soft 8 style) steel wheels, 17x8”
Goodyear Wrangler Duratrac 245/75-17 tires (pizza cutters for the snow)


Pre/Post Lift numbers

Hub to fender measurements:
Pre-lift Front = 18” Rear = 18.75”
Post-lift Front = 21.25" (Actual) Rear = 21.75" (Actual)
(21.5”/21.75” expected)

Ground to fender measurements:
Pre-lift Front = 31.25” Rear = 32”
Post-lift Front = 36.5" (Actual) Rear = 38" (Actual)
(37.75”/38.5 expected)

Ground to tc measurements
Pre-lift = 9”
Post-lift = 14" (Actual)
(13.75” expected *eliminated the TC spacers*)
Interior:
White face gauge overlays
LED gauge backlighting
RAH CD/MP3 player (replacing stock RAZ CD/tape player)
Homelink EVIC w/o TPS (replacing base EVIC)
Drivers side interior door trim replacement
L&R rear door lock actuator replacement
L&R rear seatbelt assembly replacement

Removable seat mod
Cargo area auxiliary lighting (relayed so that they come on with a switch, or the dome light above the tailgate)
Rear auxiliary 12V outlet (from a WJ Ltd)
Exterior & Cosmetics:
Front wiper arms cleanup/paint
Rear wiper arm replacement
Roof rail cleanup/paint
Lower window wipe replacement (all four windows)
Cleanup/paint two small areas of rust (hood & tailgate)
Cleanup/paint factory tow area

Cleanup cladding
Engine bay powerwash
Debadge
Paint chrome grille
Mechanical:
Complete fluid change with Amsoil synthetic products:
Oil & Filter
Transmission flush & Filter
Front Diff.
Rear Diff.
Transfer case.
Fuel filter/regulator.
Air filter.
PAI four orifice injector replacements
Spark Plugs


Rear wiper motor replacement
Hood lift arm replacement
Protection:
Upcountry/MOPAR radiator support skid
Upcountry/MOPAR transfer case skid
Hunter “Super Bull Bar” (modified)
Tank tuck mod
Recovery:
Front mounted receiver hitch with clevis points

Now available for general sale
Lighting:
Limited-style headlight housings to replace frosted stock Laredo housings
Hella Micro FF fogs for the bull bar
Hella (Optilux) 1450's (4) for a roof-mounted lightbar (uses the stock roof bow)

Cheapo chinamart backup/traliering light
Driveline:
Carolina Driveline double-cardan front driveshaft.
Future projects/mods

Full exhaust

Clean/paint stock Timberlines (5) black/graphite
265/75-16 Duratracs (or maybe TreadWright Sentinal A/Ts)


Rear mounted swing-away tire carrier (under bumper)
Removable tray mounted winch

__________________


Click to order:
WJ Stand-Alone Shackle Tabs.
WJ Modular Recovery & Bull Bar Relocation Kits.

Kris Fox
kfox@fawkesmfg.com
www.fawkesfab.com

Last edited by Fawkes; 12-12-2011 at 04:21 PM.. Reason: New Updates 12/12/11
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Unread 01-01-2011, 12:45 PM   #2
BlackDaddyZJ
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sounds like some pretty good plans. i wouldnt go with rocky road offroad, there hve been a lot of bad reviews of their customer service and their products. i would recommend IRO unless you are deadset on using RRO, just be careful.
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'94 ZJ
5.2L
IRO 4.5" Lift
35x12.5 Mickey Thompson Baja MTZ's


98 5.9
Restored and daily driven
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Unread 01-01-2011, 03:48 PM   #3
Fawkes
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Quote:
Originally Posted by BlackDaddyZJ View Post
sounds like some pretty good plans. i wouldnt go with rocky road offroad, there hve been a lot of bad reviews of their customer service and their products. i would recommend IRO unless you are deadset on using RRO, just be careful.
I understand fully.

Glenn actually helped me out and shipped the Trailblazer kit ahead of projections. So far their customer service has been superb, negative reviews by others notwithstanding. The LCA's and trackbar (as well as everything else they sent) look pretty beefy, and if worse comes to worse, I should be able to switch out the springs and spacers for 4" IRO/Zone/RC/whoever springs fairly easy.

Also note that the list above is stuff that's already sitting in the garage or paid for and in transit as of 1/1/11.

ETA: Added some color coding to the OP: Yellow = stuff that's here awaiting install, Red = stuff that's paid for and awaiting arrival, Blue = stuff that's done.

Last edited by Fawkes; 01-01-2011 at 04:01 PM..
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Unread 01-01-2011, 08:21 PM   #4
Evoluvin
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Sounds like you have it all planned out!! 213K, DAMN!
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Looking to buy a TJ in the Mid-Atlantic area ASAP!!!! Please message me with what you have.

Night Crew #357
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Unread 01-06-2011, 08:56 PM   #5
Fawkes
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Updates made to the list above (no pics, not really worthwhile).

Tomorrow afternoon starts a 24-hour time window to get the lift installed. Wish me luck.

Last edited by Fawkes; 01-09-2011 at 10:06 PM.. Reason: Spelling error. I make lots, evidently.
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Unread 01-07-2011, 08:18 AM   #6
smunns
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Good luck on the lift install. I can't wait to see it! You probably won't need that transfer case drop. I installed mine at first since it was a part of my 4" kit, but later removed it. A lot less vibes without the drop on my 4" kit. I'd try it without the drop, and then add it if you have bad vibes.
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Unread 01-07-2011, 01:11 PM   #7
Fawkes
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Quote:
Originally Posted by smunns View Post
Good luck on the lift install. I can't wait to see it! You probably won't need that transfer case drop. I installed mine at first since it was a part of my 4" kit, but later removed it. A lot less vibes without the drop on my 4" kit. I'd try it without the drop, and then add it if you have bad vibes.
Thanks for the heads up. Did you do the rear upper control arm drop with your 4" kit?
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Unread 01-07-2011, 01:16 PM   #8
smunns
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Quote:
Originally Posted by EfEmDee View Post
I understand fully.

Glenn actually helped me out and shipped the Trailblazer kit ahead of projections. So far their customer service has been superb, negative reviews by others notwithstanding. The LCA's and trackbar (as well as everything else they sent) look pretty beefy, and if worse comes to worse, I should be able to switch out the springs and spacers for 4" IRO/Zone/RC/whoever springs fairly easy.

Also note that the list above is stuff that's already sitting in the garage or paid for and in transit as of 1/1/11.

ETA: Added some color coding to the OP: Yellow = stuff that's here awaiting install, Red = stuff that's paid for and awaiting arrival, Blue = stuff that's done.
Yes. Although it's a pain to install, you want the a-arm spacer.
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Unread 01-07-2011, 06:14 PM   #9
Fawkes
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Quote:
Originally Posted by smunns View Post
Yes. Although it's a pain to install, you want the a-arm spacer.
Well then, it looks like I got a bit more to do before the rear is done (shocks, springs, spacers, endlinks and swaybar are on already).
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Unread 01-08-2011, 07:43 PM   #10
Fawkes
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Lift installed. Looks good, but need to do an alignment.

Zone needs to include more hardware (instructions and product are great)
Iron Rock needs to include photos in their install notes (hardware was present, and the product is great).
Rocky Road needs to include better hardware with more thourough instructions. The product seems good, but more thought could be put into Zerk fitting placement.

All told, it took one man ~ 16 hours. It would have taken 1/2 the time if I had a helping hand for all of 20 minutes (adjusting stuff by yourself takes forever).
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Unread 01-09-2011, 06:54 AM   #11
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After getting some rest...

Heading back to get things close to aligned (gonna be fun doing it by myself ).

Wasn't super happy with driveline geometry without the crossmember drop, so I did end up putting that on. It looks okay now, but we'll see.

While underneath, I noticed that my muffler is close to rusting through, and the annoying exhaust buzz I've been hearing for a while is the heat shield - which is now connected to the body by exatly one retainer. I'm thinking of pulling the heatshield off completely and doing a quick replacement of the muffler (Flowmaster or whatever I can pick up for cheap at Autozone or Farm & Fleet).

Front tires rub on the edge of the bumper at full lock. Looks like I'm going to have to trim.
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Unread 01-09-2011, 09:51 PM   #12
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Trimming done (for now): Front bumper front and a tiny bit off the back, inner fender well back corners and a chunk behind the fog lights. Need to come up with a way to attach the lower centerline inner fender wells to the bumper, probably forward of their current position.

I re-set the trackbar by a turn or a turn and a half, but did not do an alignment... I'm going to let a shop handle that.

The plastic shroud and totally rusted out shroud/bumper retainer are now gone. Both the skid and the bull bar mount to the same frame mounting holes, which had to be tapped. It was no fun getting the bull bar in with the skid at the same time, but I managed.

Drove around the parking lot to make sure that there was no drastic noise other than the fender rubs (now silent at full lock). Off to the alignment guys Monday or Tuesday.

ETA: Quick cellphone photo (pre-bull bar) below. I'll try and get the other photos I took uploaded when I can.
imag0419.jpg  

Last edited by Fawkes; 01-09-2011 at 10:04 PM.. Reason: Added photo
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Unread 01-10-2011, 12:47 AM   #13
MikeeN
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i bet those 17 inch steelys kill your gas mileage! But your jeepslookin realy good man!
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Unread 01-12-2011, 08:47 AM   #14
Fawkes
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Loss of ~1 MPG indicated on the commute before/after, but I have bigger issues at the moment:

http://www.jeepforum.com/forum/f310/.../#post10772701
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Unread 01-13-2011, 06:01 PM   #15
Fawkes
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I thought I did my research, but I guess I missed the fact that I need a double-cardan front DS after 2". Going to order from Carolina Driveline in the AM.
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