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Unread 10-07-2011, 01:24 AM   #1
W2001J
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1993 ZJ 
 
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Location: Grass Valley
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The Official ZJ Ford Ton Build

This is the official build thread for my 93 ZJ "Ford Ton".

My brother and I bought this 93 ZJ for $400.00 after selling his 2000 Dodge Durango and I sold my 2001 Grand Cherokee. Both were lifted, and got terrible gas mileage. We sold them for cars better on gas.

My old Jeep. 4" lift, 32's and other crap


I don't have a picture of his Durango, but who cars it's a Dodge. It had 5" lift, 33's yada yada.

The ZJ came to us looking like this. Not bad for $400.00


A rattle can paint job, Iron Rock Off Road basic 4.5" lift and 33" Wild Cats came next.


We decided some recovery was in order. We began work on a winch bumper.



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Unread 10-07-2011, 01:38 AM   #2
W2001J
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Fitted the Smittybilt XRC Winch.


And finished the welding and grinding.


Mounted everything up and painted the bumper.


Swapped out the bald Wild Cats for some good used Pro Comps, and hacked the fenders.


Took it on a camping trip to Gold Lake, California and broke some stuff.


CV axle shaft.


Broke the Smittybilt Winch after loosing 4 wheel drive due to the broken axle shaft. After many phone calls and much ranting on my part, Smittybilt replaced the entire winch free.


Attempting to make repairs at the camp site.
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Unread 10-07-2011, 01:49 AM   #3
W2001J
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Returned from the camping to to find that we also blew out all the ball joints, bent the drag link, and bent the tie rod. I guess it's time for an upgrade. Bought the Ruff Stuff GM 1 Ton Y Link steering.



During this time we also decided that the NP249 TC had to go so we swamped in a NP242 and a Iron Rock Off Road hack n tap slip yoke eliminator.

Loaded the ZJ on the car hauler for a trip to Frobot Fabrication (Agitated Pancake) for the instillation of the new ball joints and 1 ton steering.



Greg quickly got to work!

Stock steering removed.


Knuckles off to be reamed for the 1 ton tie rods ends.


New ball joints in.
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Unread 10-07-2011, 01:55 AM   #4
W2001J
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Ford 8.8

After some mishaps with the freight company (Saia), the Ford 8.8 axle arrived in my garage. Since the ZJ is still at Frobot what better thing to do then get the axle ready to install.



Cut all the old Ford brackets off with an acetylene cutting torch. Old school, I know. Hey it works.



Took the grinder to it and got the tubes ready to go. Brackets from Frobot should be picked up soon when I go get the ZJ...
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Unread 10-10-2011, 10:54 AM   #5
W2001J
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The 1 ton steering is almost finished. Just have to install the steering stabilizer and a few other odds and ends.

forumrunner_20111010_083457.jpg
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Unread 10-10-2011, 11:05 AM   #6
ibjeepin95
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Very nice. That steering looks BEEF. I would like to do that, guess I need a reamer.
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Unread 10-10-2011, 11:54 PM   #7
W2001J
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You don't need a reamer. You can just get the weld in taper inserts from Ruff Stuff. Then you just need a 7/8" drill bit.

Ruff Stuff Tapered Steering Knuckle Insert
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Unread 10-11-2011, 12:07 AM   #8
W2001J
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The 1 ton steering interfered with the sway bar mounts. Greg devised a way to grind them back for proper clearance of the tie rod and cut an additional support bracket on his Torchmate that I will weld in for extra support. A longer bolt, and it will be far better then stock.

From this....


To this....

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Unread 11-24-2011, 02:55 PM   #9
W2001J
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Found out the the centering yoke in the rear drive shaft was bad causing play in the shaft and a loud thumpisng noise while driving. This is the old centering yoke, no needle bearings caused the play in the shaft.



Also took off the old Pro Comp 33's and put on some 35's in preparation for the 6.5" lift and long arms. With all the fender trimming there is very little rubbing if any. The front passenger side rubs because the lower control arm bushing is gone causing front to back play in the arm, this caused the whole axle to move front to back.


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Unread 12-02-2011, 02:29 AM   #10
W2001J
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Stopped by Frobot Fab today and picked up the cut parts off the Torchmate to make the brackets for the Ford 8.8.


Tacked them together with my Miller and we have brackets.


Final welding will be done when they are welded to the axle.
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Unread 12-09-2011, 01:03 AM   #11
W2001J
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Made a little progress with the 8.8 swap. Started by making a block off plate for the ABS sensor.





Out with the turdy five.





I got all the brackets mounted and tacked in place. I was able to do a test fit and start final welding.....then I ran out of welding gas. Guess I will have to finish tomorrow.
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Unread 12-13-2011, 12:39 AM   #12
W2001J
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Got all the brackets for the 8.8 welded up today including the mounting bolts for the brake line distribution block and soft lines to the calipers.





Tomorrow I will run the hard line and paint. More to come.
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Unread 12-13-2011, 06:01 PM   #13
theycallmesdz
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Wow....thats looking good man!!!
Keep up the good work!
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Unread 12-14-2011, 11:46 PM   #14
W2001J
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Painted the axle today along with bending the hard brake lines. Now its a waiting game for the paint to dry as it is cold here. Tomorrow I will mount it all up....



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Unread 12-15-2011, 02:25 AM   #15
gspup
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awesome !
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