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2002 Wrangler Build

1K views 10 replies 1 participant last post by  joester1908 
#1 · (Edited)
My neighbor texted me on day. He told me he looked at an 02 TJ with high mileage for a good deal. The guy said he would hold it until the next day for my neighbor to make a decision. He decided he didn't want it, but asked if I did. I went and drove it and decided it was time to sell the DSM and pick up a TJ.



It ran a little rough and had some brake pulsation. I picked up some plugs and checked the brakes. Time for new rotors


Someone in the past installed the bumper and put the fog lights on the side.

Changed the oil and filter

and removed the lights
 
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#2 · (Edited)
Sorry for the break in photos. Photo Bucket was giving me issues.
Looks way better in my opinion

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I work at a dealership so i used our wash rack to clean the Jeep up. Ended up looking pretty good!
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Here is my dad's TJ and mine. Decided to change the plugs out due to a rough idle.
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The previous owner claimed that he took the steering column trim off to "replace something". Not sure what that means, but I found some trim on eBay
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Nice little Jeep, but it needs lift and tires. The chrome wheels kinda drive me crazy
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We had some pretty good rain. The passenger side floor board got soaked. Some research lead to this drain, which had a broken seal and was full of pine needles. Replaced that.
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I went to the Moonshiner's swap meet at the Washington State Fair. Picked up this Warn 8274 winch plate. It was covered in oil and had the fair lead welded on to it. I ground that down and put it in our parts washer.
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I took off the factory sway bar cover and cleaned up all the hardware. Turned out pretty well
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My brother decided he wanted the tube bumper. I wanted a tire carrier so I gave that to him and he let me put on the stock one
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#3 ·
So I ordered a lift for the Jeep! I ordered a Rock Krawler 3.5" short arm and SYE kit. For tires 33x10.5R15 KM2s with my discount at work, and some 15x8 ProComp Steelies.
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I pulled the winch off my Comanche and got it wired up to the TJ. I plan on putting winch controls inside the Jeep, but that will come later
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I threw my Optima in the Wrangler so I can use the side terminals
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Look what showed up! (Don't mind the remodel)
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And my tires came in
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I spooled the winch line on
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I also found a winch cover at the swap meet
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Pulled this weird bike rack thing off
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Here's the 2 Jeeps next to each other. The Comanche has chromoly shafts, 4.56 gears, ARBs and ARB covers. The front is a TJ D44 and the rear is an XJ D44. So the plan is to swap the TJ Dana 44 in the front of the Wrangler and the Wrangler D30 in the front of the Comanche. Then I'll swap the Dana 44 internals around. That way the Wrangler will be 4.56 and the Comanche will be 3.73. The Comanche was my first truck. It is awesome and I don't want to beat it up so bad off road. There is a lot more aftermarket support for the TJs.
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Here are some before photos for reference
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#4 ·
Well, the lift showed up. Here is what I did
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I have 3/4 ton steering and a Teraflex OTK knuckle on my Wrangler D44. I had to drill out my pitman arm to a larger size for the heavy duty tie rod end. For that reason, I needed to pull the arm off the Wrangler box and swap it with the one on the Comanche. No luck with that
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#5 · (Edited)
Luckily, the pitman came off the Comanche pretty easily. I just cut the one of the TJ
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Installed the double shear track bar bracket
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Here's the suspension
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When I put the 3/4 ton steering on my Comanche, I used 1 1/4" heims. The new track bar uses 1". So my dad helped me grind off 1/8" off each side.
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Welded on new sway bar brackets
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The front sits a little lower still, I assume due to the winch and bumper
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The kit came with this track bar relocation bracket
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I threw these stickers on it but I'm not sure if I like it
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I threw my dad's half doors on my Jeep
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SYE kit showed up
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I had the 4x4 shop look at my Jeep. The rear end was clunking over bumps and I could not get the track bar in very easily. They said because I tipped up my pinion angle for the SYE, I should get an offset track bar bracket, and these adapters that kick the shock mounts out, which were contacting the coil bucket.
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Not a huge fan of this Rubicon Express bracket. It's almost like its too far the other way now. Time for an adjustable track bar...
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#6 ·
Time to rebuild the NP231. I got a rebuild kit, new chain, and the SYE kit
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This bearing was a pain to get out
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My rear rack bar showed up
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Cleaned the grease off the cross member and cleaned up the surface rust
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Happened to have an old XJ shaft laying around for the rear, and because the Dana 44 is longer I had to get the front shaft shortened
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Got a great deal on this Warn rear bumper with tire carrier on Craigslist
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Remember how I said the front sat lower than the rear? I was hoping that the bumper and tire would help settle the rear of the Jeep to make it sit more level
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Wheel gap before
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#7 ·
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Had to customize the plate and bracket a little bit
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Wheel gap after. Not really much change
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Definitely happy with the look!
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Drove it to work and cleaned it up again! Really happy with how it turned out, besides it sitting unlevel
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#8 ·
OK, so I got some 2" coil spacers for the front end to help level it out
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The axle shifted on the jack, so I used my brothers winch to make the upper control arms line up
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I didn't get the springs to sit in the bucket so it sat pretty funny
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I let the weight off the springs, set them back in the buckets and was happy with how it sat
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I got the ARB compressor from my Comanche mounted in the TJ. My dad helped me mount it because he put his in the same spot. He has been a huge help through this process
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Behind my dad's Jeep is the axle that came out of my Comanche. Hopefully next week sometime my friend at work will help me swap over the internals
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The harness for power and ground fit perfectly over to the battery. The switch harness was pretty easy to run, which I just ran up to the center console
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#9 ·
Pressure washed the bottom of the Jeep so I could paint up the rear and get all the road grime off
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Took my top off and put my dad's half doors on. I really need to find a set for myself
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Here is the rear axle painted. I didn't paint the diff cover because I'm installing the ARB cover once I get the internals swapped over.
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#10 ·
Update

My friend from work helped me swap over the internals from the Comanche's Dana 44 into the TJs. Went pretty smooth. Got the air line ran and now I just need to do some plumbing for the air...
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Few hundred miles on the suspension, starting getting a pop from the rear suspension. My neighbor let me borrow his garage again and we figured out it was the left rear upper control arm.
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I installed the ARB switches in the dash. Turned out ok
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Here is the manifold I built for the solenoids and the quick disconnect. Eventually, I plan on putting another quick disconnect out by the front bumper. but for now, this will work good
[/URL]Jeep update by Joey Keith, on Flickr[/IMG]
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Took my Jeep out on the trails for the first time. This thing preforms awesome. I can't begin to explain how much of an easier time this thing has over the MJ. However, I did pop the fuse for my ARB air compressor. Works fine if you only use it for a minute, but over an extended period of use, the compressor turns off and pops both fuses...
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Really loving this Jeep. Does awesome on the trails, and a day in downtown Seattle is no problem for it either.
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Interesting. My clutch pedal linkage popped off. I was gonna get fancy with it because you can't buy the linkage without buying the master, but I ended up using some nuts and bolts
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Took my Jeep out for the second time. I didn't take too many photos because I was busy driving. lol It preformed awesome again, besides that compressor popping the fuses...I contacted ARB
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#11 ·
Unfortunately, I didn't put the door straps on when I installed my brothers tube doors. Oh well. Live and learn.
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We have had some pretty good rain. This Bikini pools up pretty bad
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My buddy sold his TJ and he sold me the sPod he had in it for a really good deal. Installed that today (with his help)
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The sPod will replace my ARB switches. Clean install. Also, ARB sent me a brand new air compressor and wiring harness. Sweet. Got that all installed. Hopefully no more air issues. I also ordered an SPod/ARB adapter harness ($18 from 4WheelParts) so I can run the ARBs through the SPod with no modification. That will be awesome.
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Just waiting on the jumper harness and I need to go to Home Depot and get a few air fittings. This is that bracket I was talking about for a quick disconnect outside the vehicle. I need to modify the manifold I made a little bit, then I'll be able to use it. Calling it a night, however.
[/URL]Jeep update by Joey Keith, on Flickr[/IMG]
 
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