5.9 ZJ build - JeepForum.com
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post #1 of 170 Old 07-14-2010, 09:55 PM Thread Starter
UTChavok
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5.9 ZJ build

Figured I'd throw this up in here. I've got it in the GC forum but it gets little input.

I started out with a 98 4.0 ZJ, 4.5" RE suspension, locked in the front 30/35. Few other goodies. Nothing to fancy.





But then she ended up looking like this.


So I was pretty dead set on a TJ when one day I drove my buddies ZJ to his house and knew I had to get another. Wanted something with a little more power so I got a 98 5.9 all blinged out. 98k on it, not to bad.


Put my old lift and other suspension parts onto the Jeep within a couple weeks. Wheeled it at Uwharrie. There are a ton more pictures in my original build. http://www.jeepforum.com/forum/f197/...thread-745638/

Heres how she sits now.




I'll post my most recent updates in another post.

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post #2 of 170 Old 07-14-2010, 10:03 PM Thread Starter
UTChavok
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So heres a short list of the plans for the ZJ.
  • Waggy D44 4.56s detroit warn premos.
  • Ford 8.8 4.56s Aussie locker and chromos to match 6x5.5
  • Radius arm "3 link" in the front using claytons crossmember and fabbed links
  • Triangulated upper 4 link in the rear
  • 5.5" coils with 35s if they tuck well. Throw a 1" spacer in there if they need a little more room.
  • Probably going to go with 35" KM2s. I've been real happy with how mine have performed.
  • 231 w/ SYE and new driveshaft

Got another set of TnT unibody stiffeners and my buddy welded them on.



I've been taking a summer welding class and bought a Hobart 140

My next attempt at some fab will be this weekend. Going to start building my sliders.

Bye bye all wheel drive. Swapped in the 231 w/ a sye and got a new shaft made at carolina driveline.


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post #3 of 170 Old 07-14-2010, 11:28 PM
Nates93yj
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awesome start looking forward to seeing more progress

NATE
2003 GMC 2500 Duramax
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post #4 of 170 Old 07-14-2010, 11:46 PM
kelso1337
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2003 TJ Wrangler 
 
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Lookin good, lookin good. I can't wait to see whats in store for this ZJ.

One question, why swap in np231? (ps I dont know squat about ZJs)

Stock 2003 Jeep TJ - 'Intense Blue'
Bought the jeep in April, found JF in May...
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post #5 of 170 Old 07-15-2010, 03:44 AM
karlo
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Nice looking zj. Seems like you're in the right track!
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post #6 of 170 Old 07-15-2010, 07:37 AM Thread Starter
UTChavok
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Quote:
Originally Posted by kelso1337 View Post
Lookin good, lookin good. I can't wait to see whats in store for this ZJ.

One question, why swap in np231? (ps I dont know squat about ZJs)
V8 ZJs came with a 249 transfer case, which is all wheel drive. Have 4 All time, neutral and 4 Lo. Wanted to have 2 wheel for the road since Id be locked front and rear.
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post #7 of 170 Old 07-15-2010, 12:59 PM Thread Starter
UTChavok
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Your order has been successfully processed! Your products will arrive at their destination within 2-5 working days.



Ordered this bad boy just now.
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post #8 of 170 Old 07-15-2010, 02:12 PM
NaeKid
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Is the FullTime-case to NP231 a straight-swap (similar year or any year), or is there something else involved with it? I'll be lifting/locking up the "LuxMobile" shortly so I will need to do something about it's full-time 'case.

Hello, my name is Vance and I am a Jeepaholic.
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post #9 of 170 Old 07-22-2010, 08:33 AM Thread Starter
UTChavok
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Quote:
Originally Posted by NaeKid View Post
Is the FullTime-case to NP231 a straight-swap (similar year or any year), or is there something else involved with it? I'll be lifting/locking up the "LuxMobile" shortly so I will need to do something about it's full-time 'case.
It is a straight swap if you find a 231 with the same length input shaft. Luckily I did so I didn't have to tear apart the cases. It's hit or miss but this thread should explain it a lot better then I ever could.

ZJ 231 Swap - MallCrawlin.com Forums
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post #10 of 170 Old 07-22-2010, 08:42 AM
woodkrawler
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I'm looking forward to seeing this build progress. I had a white 5.9L at one time and I wish I had kept it. They really are sweet Jeeps. Do you ever head up to Uwharrie?

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post #11 of 170 Old 07-22-2010, 09:09 AM Thread Starter
UTChavok
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Quote:
Originally Posted by woodkrawler View Post
I'm looking forward to seeing this build progress. I had a white 5.9L at one time and I wish I had kept it. They really are sweet Jeeps. Do you ever head up to Uwharrie?
Yeah I was so close to getting a TJ when I totaled the old ZJ but couldnt do it. Plus 5.9s are sweet, especially after I get an exhaust on it. Catching rev limiter will really turn some heads on the trails . Those two pictures of me wheeling the niner are from Uwharrie. Ive been there a couple times and really like it, not the hardest trails but definitely fun.
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post #12 of 170 Old 07-22-2010, 05:45 PM
xsivtork
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vibration

did you have a vibration after the lift before the transfer case change. i was told not too lift mine as it would have vibration becuase of the awd?
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post #13 of 170 Old 07-22-2010, 08:09 PM Thread Starter
UTChavok
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Quote:
Originally Posted by xsivtork View Post
did you have a vibration after the lift before the transfer case change. i was told not too lift mine as it would have vibration becuase of the awd?
Honestly I did not have any driveline vibes that I could notice. My tires vibe a little bit becuase their so worn but that was noticable before and after the tcase swap. My tires would lock up in turns and chirp a little due to the AWD but that happened before and after the lift and tire swap.
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post #14 of 170 Old 07-23-2010, 09:58 AM
MoparBoy01
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Nice looking ZJ. I have been working on mine for the past couple months getting her all ready.

1998 ZJ 4.0L-Trail Rig
1998 ZJ Black 5.9L-Prerunner/Daily Driver
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post #15 of 170 Old 07-23-2010, 10:11 AM
SkyHigh
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Sweet 5.9 I still miss ours. Sold back in 05, shoulda kept it.

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