[tacweapon]

Here is my build thread for my 1996 ZJ. I am going to try and keep it as up to date as I can. Feel free to comment and give suggestions on my build.

Year
1996

Model:
ZJ

Engine:
5.2L V8

Transmission:
Stock

Transfer Case:
NP242

Front Axle:
D30

Rear Axle:
D44A

Axle Gear Ratio:
Stock 3.73 for now

Suspension:
7in Clayton Long Arm Lift, Pitman Drop Arm, Adj Trackbar,Ext Brake Lines

Tires:
Mickey Thompson Baja Claw

Wheels:
Cragar D-Windows

Armor:
Homemade Rock Sliders, Diff Shields, ARB Deluxe Bumper

Recovery Gear:
Warn Winch, Tow Strap, Hi-Lift, Shovel, Clevis Hooks

Accessories:
Hella 500FF, Kargo Master Roof Rack, Rhino Lined, Saferi Snorkel,

Future Modifications:
Regear to 4.56 or 4.88, Lockers, Hella 1000FF and Pro Comp 130W lights, Rear Tire Carrier, Engine Skid, Gas Tank Skid, TC Skid




Well here is my Jeep. My first Jeep was a 2000 XJ that I sank in a 5.5ft deep water hole after that happened I began my search for a new Jeep.

I found this one in a Local Classified, I went and test drove it and decided to buy it, I bought it for $3,000 knowing it needed some work.

What I knew it needed
Passenger Quarter Window and molding
I needed to put the Front Driveshaft in

What it looked like the Day I bought it


Sitting in front of my Mechanics shop during the last snow storm

I later found out that I had a Tom Woods Front Drive shaft that was shot after I put it back in and I started going down the road and got some real bad driveline vibrations and then I lost all power, it turns out that the front driveshaft separeted and caused the transfer case to grenade so my transfer case was in 3 pieces while I was sitting on the side of a major road waiting to get towed. I got it towed out and then bought a NP242 Transfer Case and stock Rear Drive Shaft I had a Front Drive Shaft made for me and it is super beefy it makes the Tom Woods look like a twig. I got the rear window installed also.

The first time I was going to wheel it I found out that the previous owner decided to make there own Discos out of Bar Stock and they were held in place using Hitch Pins. The hitch Pins were bent in the manner that you would expect Cotter pins to be so I cut the hitch pins of using a Dremel and then found out that I cant rotate the homade discos to get them out of the way so I just took them off and I have some Discos on order.

First Time Wheeling
I went to a buddies house so that if something happened I wouldnt be out in the middle of nowhere.

While Wheelin I found out that I need to get the linkage looked at for the Transfer Case, everything except 4Lo is good but 4Lo will occusionally slip out. I also found out that I need to work on the Winch, the winch motor is fine but the line appears to have not been spooled correctly last time because there a a bite of line that is not wrapped but has line on top of it and it the process of trying to get it the line appears to have come off the spool, I can see a broke terminal end on the line so it looks like that is all that is wrong with it.

First Time Hi-Centered




The snow covered up a huge rock and I ended up catching my front passenger side long arm on it we ended jacking the Jeep up with the Hi-Lift and placing logs under the front tire to drive off of it, I got the front long arm off only to get the rear long arm caught so we jacked it up again and put the logs under it I drove off again.

First Time testing the flex





I didnt quite max out the rear I have about 2 inches left and about 3 inches in the front.
When I drove up on it I didnt think I was flexing, my buddie told me to drove up on it to see how much I can get and once I was up on it I told Im dont think its flexing much but we got out and looked and it was flexing almost max.

The day that I was testing out the jeep I hit a 3 foot mound of what I thought was snow but it had compacted into ice and I ended up breaking my steering box. I took the Jeep to Merchants cause I thought it was just a busted rubber gasket and my normal mechanic was closed for New Years and they told me that it was going to cost 1012 to fix, I took it to my Mechanic on Monday I found a Steering Box from a local Junkyard for $65 so for parts, fluids and labor I ended up paying $330 to fix it.

I will try and keep this fairly up to date if you have any questions let me know

[Mazdarx]

Looks like you got a good deal on that rig. I remember somebody posting on here asking if they should buy that Jeep, not sure if that was you though.

[bigbluezj94]

nice rig. whats with the red white and blue diff covers lol.

[zjzach]

is the light on you passenger pillar a cop style spotlight or how is it mounted?

having claytons, an arb w winch, sliders, roof rack ect ya know even with some work 3 grand isnt a bad price for all it has. good find. welcome to the gc side.

[tacweapon]

Originally Posted by Mazdarx

Looks like you got a good deal on that rig. I remember somebody posting on here asking if they should buy that Jeep, not sure if that was you though.

Yeah that was me, I figured it was a good deal but I wanted to make sure

[tacweapon]

Originally Posted by bigbluezj94

nice rig. whats with the red white and blue diff covers lol.

The guy told me they were Skyjacker Diff Covers but I havent look to see if thats what they really are, they do say Skyjacker on them though

[tacweapon]

Originally Posted by zjzach

is the light on you passenger pillar a cop style spotlight or how is it mounted?

having claytons, an arb w winch, sliders, roof rack ect ya know even with some work 3 grand isnt a bad price for all it has. good find. welcome to the gc side.

Yeah it is a cop spotlight, I didnt mount it but it appears to be a hole drilled through the A-Pillar and there is a notch cut out of the door for it

[tacweapon]

Heres a few more pics I took today just driving around doing some very mild hill climbs

[HaViiK]

Excellent dude...What size roof rack is that?

BTW, I see your from Harrisonburg, Im from around Lynchburg!

[tacweapon]

Originally Posted by HaViiK01WJ

Excellent dude...What size roof rack is that?

BTW, I see your from Harrisonburg, Im from around Lynchburg!

I think its the Kargo Master 52x60 but Im not sure

[zjzach]

I remember seeing on an episode of Xtreme 4x4 that if you turn those baja claws so the tread is backwards you actually get better off road traction. according to Ian

[Tiggerrrrr]

Originally Posted by bigbluezj94

nice rig. whats with the red white and blue diff covers lol.

They're the new super awesome Pepsi diff covers.

[tacweapon]

Well I went wheelin on Saturday and lost power steering again, I took it to the shop and it turns out that the hi-pressure line came loose so it was an easy fix but while it was there I found out that both my motor mounts are shot so I guess I am adding it to the list of things to fix.

[tacweapon]

I am replacing the motor mounts on Friday and getting the transfer case linkage looked at, so hopefully I will have some more info and pics soon

[Greengc4x4]

Have you concidered learning to work on your Jeep on your own? Jeeps are much easier to work on than you would think, and it can be enjoyable too, atleast for me, but Im not the most normal person out there