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Unread 04-14-2011, 08:41 PM   #1
Jeepinty
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2002 TJ Wrangler 
 
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Location: Groves, Texas
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2002 TJ, Tons, Stretched, 40's

I already have a thread about this build in the TJ section but there is quite a bit of tech stuff and a lot of talking in it so I thought I would make a thread here to showcase the build with slightly less chat. Hopefully it isn't a problem.

Background:

I bought the TJ new in 2002 and immediately began wheeling it on a newly wed, full time college student budget, ie...no money. It ended up with a thrown together, half assed 4inch lift and 35 inch tires. I wheeled it for a while and realized I was tearing it up too fast and broke down and bought a wrecked but wheelable 1998 TJ which I eventually backhalved. The 2002 TJ was retired to basically DD duty where it served me well for years. Eventually I sold the 1998 TJ to buy a 4 wheeler (regret) and over the last or so I've began to slowly wheel the 2002 again.

Finally, last summer I graduated college after going on and off for several years and earlier this year landed a good job. That leaves me with more money and a better schedule for making wheeling trips. Not that I am rolling in dough but I finally have a little extra money (between the kid and a pregnant wife who really wants to build a new house) to where I finally decided I was tired of being the smallest jeep at every run. Also, after purchasing my wife a new to us Tahoe I took "ownership" of our 2008 Chevy truck as a DD and now the jeep is merely an offroad and weekend toy.


Before the build:

Jeep: 2002 TJ Sport

Engine: 4.0

Trans: Stock auto (3pd)

Xfer: NP 231 w/ SS SYE

Front: D30, 3.73, Lockright

Rear: D44, 3.73, Trackloc

Lift: 4" RC

Shocks: 4" RC

Tires/Wheels: 35" KM2s, 15x8 American Eagle

Battery: Exide Orbital

Armor: Sun Performance rockers






Plans:

Engine: 4.0 (upgrade intake)

Trans: Stock auto (3pd)

Xfer: NP 231 w/ SS SYE (Atlas upgrade next season)

Front: CUCV D60, 4.56, Detroit, swapped long/short side

Rear: CUCV 14b, 4.56, Detroit, disc brake swap

Lift: 4" RC front coils, undecided rear coils, 10-12" stretch

Arms: Custom 3/4 link, 1.75" .120 uppers and 2.0 .250 lowers all DOM
w/Johnny Joints at all ends

Shocks: undecided, maybe Poly BBCS or Bilstein

Tires/Wheels: 40" MTRs new style/stock H2 hummer wheels

Armor: Genright Stretch Corners, Genright Mini-boatside Rockers, WRF tube
fenders w/new inner fender

Battery: Optima

Cage: Undecided, through the dash full cage

Fuel tank: RCI cell, KORE ring (probably getting sunk into floor)

Steering: 1.5 .250 DOM, 3/4" Chromo heims, Redneck Ram Hydro Assist



I found a decent deal on a running CUCV military truck. The plan was to buy the truck, beat it until the engine, tranny, xfer case crapped out then part it out and keep the axles. Unfortunately when it came time to pick it up it wouldn't fit on my trailer so I made a deal for just the axles. OMFG, a fully decked 14b weighs A LOT! My back was jacked for weeks.




Tear down was.......interesting. There weren't many miles on them but they were hard miles. I was praying I wouldn't have to change the king pins themselves after hearing horror stories. Turns out they are usable, I will be changing everything but the actual kingpin.













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Unread 04-14-2011, 08:49 PM   #2
Jeepinty
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2002 TJ Wrangler 
 
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D30 shaft vs D60 30/35 spline shafts






One problem was the front differential was on the wrong side. I originally planned on trying to run it on the passenger side with a flipped D300 but changed my mind after hearing horror stories about setting them up. So, we did this.












Drivers side drop Chevy D60




Axles cleaned up and on rolling stands




Scored 40" MTRs and a set of H2 wheels




Kore rear brackets, using ballistic coil buckets




Time to shave a 14b







By this time I had used a ridiculous amount of sawsall blades all over the jeep.

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Unread 04-14-2011, 08:56 PM   #3
Jeepinty
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Rear disc brakes




Reassembled minus shafts




Random shots of the rear suspension coming together. I didn't have a plan per say other than to stretch the rear 10-11". My original plan was to notch the frame rearward to accomodate a new coil bucket. I briefly thought about backhalving the entire frame for a new 2x4 frame but figured I could always do that later if needed.















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Unread 04-14-2011, 09:06 PM   #4
Jeepinty
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Used PVC to mock up the control arms before cutting. At $18/ft or whatever I didn't feel like screwing up a length of 2.0 .250 DOM










Full stuff












Sitting on its own






Corners, still need to trim/clean fenders






Out with the old, in with the new






And that's where I am now. Waiting on my knuckles to be sand blasted so I can start putting the D60 back together and working on the front suspension. I still need to pull the rear out for final welding/cleaning/painting but it shouldn't take more than a day when I do. Tons of little details left to sort and do but I'm taking it as it comes. I had hoped it to me done by now but we had some setbacks and things come up but it's back on track now and I try to work on it at least a few days a week.

I work a 12hr rotating shift days and nights so my schedule is wierd but I work when I can. Here is a little list I put together to keep me on track.

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Unread 04-14-2011, 09:12 PM   #5
BriansCJ
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Any more detail on how you swapped and rewelded the D60?
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Unread 04-14-2011, 09:35 PM   #6
Jeepinty
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There is some more detail in my thread in the TJ tech section but its really as easy as it looks. It is the 3rd one my buddy has done this way the last being on an LJ with 42s and a Hemi.

Making sure to measure off the inside of the diff so the side will be the same length just swapped. Thus I will be able to use the same shafts just on different sides. Cut through with bandsaw, bevel the crap out of the tubes, align and start welding. Probably 6 or 7 passes per side.
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Unread 04-21-2011, 02:37 AM   #7
Jeepinty
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Got my front brackets, 14b diff cover and pinion guard in yesterday. Getting off nights tomorrow night and hope to make some progress on the front this weekend. First priority is reassembling the D60.
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Unread 04-21-2011, 12:22 PM   #8
SaxManClay
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Wow looks awesome! I'll be following this one.
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Unread 04-24-2011, 04:45 PM   #9
Jeepinty
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Between work and the holiday weekend with the family I haven't really been able to mess with the jeep. Got another week off starting end of next week so I plan on doing as much as I can then since the baby will be here in about a month. Most of the stuff I have been able to do is just small, easy stuff that I can do without leaving the pregnant wife with a 3 year old bouncing off the walls for long.
I did get my front brackets and diff cover in and I had the knuckles on the Dana 60 media blasted and painted. I started marking the front end under the jeep but I need to read up a little before I start burning stuff in. What caster angle am I looking for on the front? I am seeing + 4-6 deg. in most places. I realize I can adjust it once the arms are installed but I would like to get it as close as possible without adjusting the arms.
Anyways, here are a few pics for everyone. Nothing special but better than nothing.

Ballistic brackets in a pile.


A few tack welds later.




One primer, one paint. They are both drying now in the driveway.


Diff cover, I was a little disappointed in this. I ordered the welded one since they "machine" them afterwards to ensure a fit. They welded the cover but it looks like they let a 4 year old after it with a grinder to try and clean up the welds. They are halfway ground down with a lot of griding scars on the cover. Honestly it doesn't bother me enough to make a stink of it but I can see where someone that was building a decent looking rig wouldn't want this on their 14b.


Just primer in this pic. The actual black paint is drying in the driveway now.
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Unread 04-24-2011, 05:26 PM   #10
wushaw
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There is something you could have done before welding the tubes back on and that was to get the caster & pinion angle as close to where you want it before sticking them together, now you will be limited as to what caster you will have since pinion angle trumps caster angle.

My Dynatrac is 3.5 degs with the pinion pointed straight at the ft. yoke and It would be better with 6.

Something to think about on the next one
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Unread 04-24-2011, 06:37 PM   #11
Jeepinty
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We actually set the angle off of another jeep he had in his shop. At approximately ride height with the pinion close to ride angle I measure around 5 deg. Granded its all ballpark but I believe it will be close enought for the girls I go with. Thanks for the heads up, I forgot to mention that in this thread.
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Unread 04-24-2011, 08:47 PM   #12
getgnar
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so awesome!!
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Unread 04-25-2011, 08:39 AM   #13
Jeepinty
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Quote:
Originally Posted by getgnar View Post
so awesome!!
Thanks, I have a long way to go. Wish I had more free time to work on it.
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Unread 05-01-2011, 08:11 PM   #14
Jeepinty
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Well decided to start mocking the axle up without assembling it first to save my back. I'll put it back together once I get everything tacked in so I can cycle the suspensing with tires. One thing holding me up is I want to build a truss for the front like the rear out of 3/8" thick 3" wide flat bar. I don't really care to weld the UCA mount to the housing but I need to track down the metal to build this first.

It took forever to weld up the front brackets tonight after I modified one for fitting over the tube sleeve on the driver side. I managed to get them tacked on the housing in the correct (I hope) spots before it got too dark. Coil buckets at 0 deg and knuckles right at 6 deg. Here are some pics of the little bit of work I got done today.


Modded to fit coil bucket






Enought heat?







The welds turned out ok but I was getting a little more splatter than I expected. It was pretty breezy outside, think that was the cause?












Randoms of mocking them up.















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Unread 05-12-2011, 10:22 AM   #15
Jeepinty
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Well I wasn't sure things could go any slower but with my wife about to pop and work getting busier they apparently can.
I didn't really get anything done this week except start the bridge/truss, rotate the coil buckets and put the outers back on . Between Dr. visits and other family stuff I have been stretched lately. Maybe after the baby is born in a week or two I will have some more free time........right......




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