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-   -   bclark11's 2004 D44 TJ Sport Build Thread (http://www.jeepforum.com/forum/f22/bclark11s-2004-d44-tj-sport-build-thread-1303875/)

bclark11 12-20-2011 03:31 PM

Thought I would start a build thread for my recently acquired 2004 Jeep Wrangler Sport. This TJ came from the factory with a Dana 44 rear axle and 4 wheel disc brakes, hard top only. The rest of the factory specs are in my profile. I will be updating this thread periodically as I get new parts in a such. At the time of posting this initial comment I have already completed same basic projects. I will go through and recap each of those to the best of my ability to bring the build current.

Here is a list of mods to look forward to:

1. Already Completed in Chronological Order (some may seem silly but I want to be thorough for my own records)

Removed Factory Side Steps
Installed Aftermarket Alarm System and Door Actuators
Replaced all Factory Speakers Including Center Console SubWoofer
Installed SmittyBuilt Oh SH*T Grab Handles Front and Rear
Installed Rugged Ridge Hood Lock (removed and returned... what a POS)
Replaced Factory Steering Dampner with Teraflex 9550 Steering Stabilizer
Installed JF Decal :2thumbsup:
Riddler D44 Diff Cover & Lube Locker
New D44 Axle Seals, Bearings, and Retaining Rings
Teraflex 3T 3" Lift Kit
Teraflex Transfer Case Lowering Kit (removed and available for sale $25?...)
Bilstein 5100 Shock Absorbers Front and Rear
Teraflex Adjustable Front Track Bar
JKS Quicker Disconects Sway Bar Links
Removed "Sport" Decals
Paint Frame and Diff Covers
ZJ Tierod Swap
New Draglink and Tie Rod Ends
Painted Fender Flares (Front)
305/70/R16 Mickey Thompson Baja MTZ on 16" Moabs
Rear Tailgate Door Lock Actuator and Jam Contact
JKS MML
JKS BL
Mopar Flat Front Bumper Caps
31 Tooth Speedo Gear
Door Jam Contacts For Door Lock Actuators (Painless Wiring on doors and junk yard third brake light contact on tailgate)
Savvy Aluminum Control Arms (Lowers front and rear and upper rears)
Currie Control Arms (Upper fronts)
Oversized Spare Tire Carrier and 3rd Brake Light Extension Brackets (sucks/forsale)
Spare Tire (16" Moab with a 33" BFG AT for now...)
Door Lock Switch
Diehard Platinum Battery
Dirtworx Rear Bumper/Tire Carrier
Light Dot Style Third Brake Lights (3/4 inch LED's)
GP-Fab Rear Bumper Frame Tie-Ins
Johnny Joint Front Axle Housing Kit
Advanced Adapters SYE kit
Carolina Driveline Rear CV style Driveline
JKS CV Rear Track Bar Bracket
Teraflex Rear Shock Relocaters
ROKMEN Belly Up TCase Skid
New Trans Mount

2. Items Purchased Awaiting Install

3/4 inch Teraflex Front Spring Spacers (Wont really need until I get new a heavy bumper/winch)
Royal Purple Syncromax for the Trans
LED Windshield Lights


3. Future Projects
Novak Shifter Cable
ROKMEN Mercenary Front Bumper w/ Tube
LED Light Bar for Front Bumper
Rock Rails with Tube Step (Brand Undecided, probably ROKMEN)
Purchase and Install Backetry for Soft Top Options
Steering Box Skid
ROKMEN Engine Skid
Savvy or ROKMEN Gas Tank Skid
Rear Main Seal Replacement
CB Radio
Regear to 4.56 Locked
Winch w/ Synthetic Line

bclark11 12-21-2011 08:12 PM

2 Attachment(s)
Attachment 319492

The day I bought her on the show room floor. Carmax had no idea what they had. Mint condish TJ with 35k miles and a factory D44. Suckas.


How it sits now...

bclark11 12-21-2011 08:14 PM

6 Attachment(s)
Attachment 319495

With side steps...



Attachment 319496

Without... You be the judge.





Attachment 319498

Attachment 319497

Installed the Tera 9550 SS.



Merry Early Christmas to meeeee!



Attachment 319500

Got the first piece of my lift kit in!!! Rear shocks.

Attachment 319486

And got a torque wrench...

bclark11 12-23-2011 07:43 AM

2 Attachment(s)
Attachment 320075

Brown Santa brought me a Riddler Dif cover and lube locker. This thing is so freaking heavy.



Attachment 320076

Also, the tailgate storage system came in. Yay for no more bulky duffle bag of tools and such taking up room in my cargo area. I hope this thing installs easy. Update: I actually retuned this... couldn't get it to lay flat against the tailgate... was all wavy. Returned along with my Rugged Ridge Hood Lock and the Teraflex 9550's towards the Bilstein 5100's. Was an even trade.

bclark11 12-24-2011 09:26 PM

1 Attachment(s)
Attachment 320729

Front shocks in. Still waiting for the Teraflex front trackbar and 3t 3" lift kit.

bclark11 12-31-2011 12:37 AM

2 Attachment(s)
Attachment 323411

Tera adj track bar!! Thanks to the mom-in-law for the awesome Christmas present.



Attachment 323412

Also, my JKS quicker discos came in today. Big thanks to 4x4groupbuy.com for the deal on these.

TJRHD 12-31-2011 05:43 AM

That is a slick jeep, I will be watching your build. Good Luck.

bclark11 01-02-2012 08:57 PM

Quote:

Originally Posted by TJRHD
That is a slick jeep, I will be watching your build. Good Luck.

Thanks dude! The progress should pick up soon. Lift kit coming in tomorrow!!

bclark11 01-02-2012 09:00 PM

1 Attachment(s)
Attachment 324697

The wife is starting to get pissed about the Jeep parts stacking up in the living room...

jeepinjellie 01-02-2012 09:19 PM

How is the tailgate storage system working out?? I like it. Where can I get one??

bclark11 01-03-2012 07:53 AM

Quote:

Originally Posted by jeepinjellie (Post 12783413)
How is the tailgate storage system working out?? I like it. Where can I get one??

I haven't had the time to install it yet. I will post a pic and mini review as soon as i get it done! :highfive:

bclark11 01-07-2012 11:38 AM

1 Attachment(s)
Finally got all the peices together for my 3" lift!!!!! Time to git-ir-dun. :cheers:

bclark11 01-07-2012 11:40 AM

1 Attachment(s)
Also, got a great deal on a windshield header!!!! 20 bucks from a fellow jeeper on CL.

TJRHD 01-07-2012 11:40 AM

go go go go go do it

bclark11 01-17-2012 03:42 PM

13 Attachment(s)
Got my axle leak fixed this weekend. Followed Stu's thread and the FSM. All and all, it was a pretty easy install. Took me a better part of the day as this is the first time i've done this. Partly because I had to wait a couple hours for 4WheelParts to press on the the bearing and retaining ring.

A local shop quoted me $500 to do the whole job... F-That! That saved money will go in my tire fund. HA! Watch me try to convince my wife of that.

Let's Git Ir Dun.

Also, I put on the new Riddler diff cover.

Here are the pics:

Jacking her up.

Attachment 331917


Shot of the brake caliper plate.. i had already cleaned off the gear oil but you can see the grime build up around the axle tube where the leak was.
Attachment 331918


That stuff smells like death.
Attachment 331916


Removing the brake caliper.
Attachment 331919


Here's the cleaned disk ready to go back on.
Attachment 331928


Dirty axle shaft.. you can see one of the retaining plate bolts through the hole in the hub.
Attachment 331927


Drilled a 1/4" hole in the bearing retainer, then hit it with the dremel a bit. Two whacks with a chisel and it popped loose. Now on to the bearing.
Attachment 331924


Here you can see that the race has been cut and I have started on the bearing cage.
Attachment 331921


Here is a pic of the last part of the bearing (not sure what it is called) it is the part that is under pressure on the axle shaft. This thing was the hardest to get off because it is tapered down towards the axle. very easy to slip with the Dremel and hit the axle shaft. I found that wrapping a thick piece of cardboard around the shaft offered a bit of protection.
Attachment 331922


Here are all of the parts that had to come off.
Attachment 331925


Here is the cleaned axle shaft with the new parts waiting to be pressed on. Brought it to my local 4WheelParts store. They pressed them on for 30 bucks.
Attachment 331926


Here is the Riddler diff cover installed. You can see the clearance with the gas tank. I wonder if I will have any interference after my lift.... hmmmmmm any one have some experience with this?
Attachment 331932


PUBLIC SERVICE ANNOUNCEMENT! Do not torque your diff cover bolts to the lube locker specifications! It says to torque to 35 ft/lbs! I thought this seemed high but tried it any way. Broke off the bolt head and the treads were stuck in my axle housing!!! I was sooo pissed. Called Riddler and talked to Nick, he said that he would talk to the owner and get back to me. Got a call back in like 5 minutes saying that they have received a few calls about this happening. He said that they have no idea where Lube Locker got those torque specs. Said that 35 ft/lbs was waaaaaaaaay too much torque for a 5/16ths bolt. Told me to drill a 1/8th inch hold in the bolt and take it out with an "Easy Out". So I went to the auto parts store and get a EasyOut, started to drill out the bolt and realized that it was finger loose... so I grabbed some needle nose pliers and turned it out pretty easily. That sucked... at least I got a new tool out of the situation. I am sure that the EasyOut will come in handy one of these days. Great customer service at Riddler... I couldn't even find a number for LubeLocker and I am a professional Googler.
Attachment 331929


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