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oalali 02-23-2012 03:32 AM

Project Rust Bucket
 
Hi Guys !

I believe that my project would benefit greatly from your expertise and guidance. Therefore, I'm posting it here. :)

Last June, I bought a 1998 Jeep Wrangler TJ. It is my first Jeep and I bought it for AED8000 (aprox. $2200). The car have done 144kms (aprox. 88k Miles) here are some photos from the classified ad:

http://i1169.photobucket.com/albums/...1052011_01.jpg

http://i1169.photobucket.com/albums/...1052011_04.jpg

http://i1169.photobucket.com/albums/...1052011_05.jpg

http://i1169.photobucket.com/albums/...1052011_02.jpg

... and here is some of the specs and general condition notes:

- stock 4.0L engine in good condition.
- K&N Filter and Borla headers and exhaust system.
- AX15 manual transmission.
- Stock front Dana 30.
- Stock Rear Dana 35.
- 2" budget boost with stock rear shocks and RC in the front.
- 31x10.5R15 All Terrain BFGoodRich T/A fitted on 15x8 GT wheels
- Front Tube bumper and Rear Warn Bumper.

some of the problems with it:

- the 4th Gear is broken
- The front axle housing is bent
- The Rear axle needs new shaft and Ring gear.
- the window wiper only work at one speed.
- A/c only blows upwards.
- some of the gauge cluster lights are not working
- Minor and Major Rust around the exterior ,interior and under the carpet. :thumbdown: But the Frame is Rust Free! :2thumbsup:

My plan is to build it into a capable desert toy that is street friendly. Regulations are very strict in my country so I need to make sure that what every modifications I add are street legal.


35" tires, High line kit, and a 4.6L stroker engine are some of the things in my list. :drool: It is good to dream ! :rofl:

To be Continued ..

oalali 02-23-2012 11:04 AM

So, I'm starting the Project by replacing all the the bad parts.

Few visits to the scrap yards and I found those:

Front Rubicon Dana 44 with Factory Rubicon locker and 4.1 gear ratio ($600)
http://i1169.photobucket.com/albums/...na44_front.jpg

Rear Standard Dana 44 with LSD ($400)
http://i1169.photobucket.com/albums/...ear_dana44.jpg

NV3550 Manual Gearbox from a 2003 TJ ($800)
No pictures .. Sorry .. :o

The gearbox was swapped at the scrap yard. I took the axles back to the shop to prepare them for assembly.. :)

So, Here is the current plan for the axles:

Front Rubicon Dana 44:
- Retain the Rubicon locker
- Motive Gear 4.88 Thick Ring and Pinion
- G2 axle & Gear Master Installation kit for Rubicon Dana 44
- RCV Performance 30 Spline CV Shafts Dana 44
- Synergy Suspension Inner axle Sleeve
- Black Magic Brake Pads, Centric Premium Rotors and Premium Calipers
- Riddler Differential cover.

Rear Dana 44:
- ARB RD116 Air locker
- Motive Gear 4.88 Thick Ring and Pinion
- G2 Axle & Gear Master Installation Kit for Dana 44
- Ten Factory 30 Spline axle shafts
- Superior Super Truss Kit for Dana 44

oalali 02-24-2012 09:36 AM

Several months later, I got all the parts I need to fix those axles:

First, a Dana 30 vs Dana 44 axle shafts:
http://i1169.photobucket.com/albums/...t/IMG_2093.jpg

I'm really glad that I upgraded..

Motive Gear 4.88 Ring and Pinion for the front and the back.
http://i1169.photobucket.com/albums/...t/IMG_2035.jpg

G2 Master Rebuild kit
http://i1169.photobucket.com/albums/...t/IMG_2034.jpg
I bought two different model for the standard Dana 44 and the Rubicon Dana 44. I really couldn't tell the difference between the two..

Synergy Inner Axle Sleeve
http://i1169.photobucket.com/albums/...t/IMG_2039.jpg
I hope that this will be enough to prevent the front axle tubes from getting bent.

RCV Performance Axle Shafts for the front:
http://i1169.photobucket.com/albums/...t/IMG_2041.jpg
I just can't wait to try those .. :drool:

Superior Axle Truss Kit
http://i1169.photobucket.com/albums/...t/IMG_2038.jpg
I loved the fact that I don't need to weld those in. Smart design if you ask me!

G2 Rear axle shafts
http://i1169.photobucket.com/albums/...t/IMG_2033.jpg
I really wanted to get Superior Evolution but couldn't find any in stock. So I opted for those instead. I hope that they will perform as good as they look.

Sgt.Fuzz 02-24-2012 12:46 PM

Impressive purchases.

shoeless 02-24-2012 01:03 PM

Quote:

Originally Posted by oalali (Post 13108564)
- A/c only blows upwards.

Do you mean through the defrost vents in front of the windshield?

If so, mines does this from time to time. What happens to mine is a vacuum line gets disconnected under the hood. It's #5 in picture here, on the side of the intake towards the back. If that's not it, make sure to check the length of the vacuum line as shown in the drawing. Otherwise it could be the blend door under the dash.

http://i59.photobucket.com/albums/g3.../Jeepacvac.gif

oalali 02-25-2012 11:35 AM

Quote:

Originally Posted by DaFuzz (Post 13117410)
Impressive purchases.

I have to import almost everything. But Thankfully, the sellers in the US are always coopertaive and ready to help ! :)

oalali 02-25-2012 11:35 AM

Quote:

Originally Posted by shoeless (Post 13117530)
Do you mean through the defrost vents in front of the windshield?

If so, mines does this from time to time. What happens to mine is a vacuum line gets disconnected under the hood. It's #5 in picture here, on the side of the intake towards the back. If that's not it, make sure to check the length of the vacuum line as shown in the drawing. Otherwise it could be the blend door under the dash.

http://i59.photobucket.com/albums/g3.../Jeepacvac.gif

Thanks ! I will try this once my car back ! :cool:

oalali 02-25-2012 01:44 PM

Installing the axle items
 
So, here are some updates:

First, both Front and Rear axles were stripped to bare housing, and then cleaned using a steam pressure washer. The front axle was slightly bent and was easily fixed.

http://i1169.photobucket.com/albums/...t/IMG_2090.jpg

Then we installed and welded Inner sleeves
http://i1169.photobucket.com/albums/...t/IMG_1208.jpg

After that, both axles housings were sand blasted, painted and mounted on RB for the final assembly
http://i1169.photobucket.com/albums/...t/IMG_2095.jpg

http://i1169.photobucket.com/albums/...t/IMG_2098.jpg

oalali 02-26-2012 01:22 PM

The reassambly have finally began:

ARB Air locker VS Factory Rubicon Air Locker
http://i1169.photobucket.com/albums/...t/IMG_2105.jpg

The Rear is almost done
http://i1169.photobucket.com/albums/...t/IMG_1220.jpg
note the Superior Truss kit is also almost done.

The Rear Axle Shafts are also done
http://i1169.photobucket.com/albums/...t/IMG_1221.jpg
I wonder what people think about Ten Factory Axle shafts and how they compare to G2 and other brands ? :confused:

We also Temporary installed the front Differential Cover to check if it rubs against anything..
http://i1169.photobucket.com/albums/...t/IMG_1248.jpg
I might end up using the stock differential cover if this one proved to be problematic... :(

The Rear Locker will be connected to my ARB Twin AIR Compressor. The Compressor is mounted on the Left Battery Try.
http://i1169.photobucket.com/albums/...t/IMG_0909.jpg
I removed the Try and then drilled new Mounting holes. It was tight, but otherwise a perfect fit. :2thumbsup:

I'm still debating however if I should use this compressor to operate the front locker or use the factory rubicon compressor.. :confused:

My new tires have also arrived. I bought BFGoodrich Mud Terrain KM2 35x12.5R15. Here is a picture to compare it with current "temporary" Cooper STT 33x12.5R15
http://i1169.photobucket.com/albums/...t/IMG_2032.jpg
Unfortunately, I won't be able to use them before installing the Highline kit which will be delivered on March 15th ... :(

map93xj 02-26-2012 02:54 PM

"I 'm still debating however if I should use this compressor to operate the front locker or use the factory rubicon compressor.. :confused:"

You can't use the ARB compressor to run the factory locker. ARB and Rubi lockers run on different air pressure. So you will need the factory compressor for the front locker. Nice build by the way.

oalali 02-27-2012 03:24 AM

Thanks ! :) I hope it gets as half a good looking as yours ! :D

Yes, I understand that the ARB compressor works at something like 100psi and the Rubicon locker works at 5 psi.

I was thinking about getting an ARB Solenoid and then use a 0-10 Pressure regulator. like this one:
http://fluidpowertraining.net/upload...672c1a4ee8.jpg

BTW guys, can anyone recommend a replacement to the stock ARB air line ?

oalali 02-28-2012 12:09 AM

The Rear axle is almost done:

http://i1169.photobucket.com/albums/...t/IMG_2107.jpg

Test fitting the rear Drums
http://i1169.photobucket.com/albums/...t/IMG_2117.jpg
I'm going take it back off to install new Brake Shoes and machine the Inner surface of the drum.
Well it be a good idea to pain the drum from outside as well ?? :confused:
I wanted to change it but the dealer have nothing in stock ! :mad:

Here is a picture of my temporary lift kit
http://i1169.photobucket.com/albums/...t/IMG_2115.jpg
Iron Man 2.5" lift + Rancho 9000xl. I'm planning to install a 2" bump stops to fit the 33" tires until I get the Highline kit.

Speaking of Bump stops, this is what is lift of it.. :o
http://i1169.photobucket.com/albums/...t/IMG_2116.jpg
I'm planning to do something about it in the future.. Should I replace it with some thing like Teraflex's Speed bumps? or just replace it with a stock unit ? :confused:

We also almost finished the front. The Ring and Pinion Job is done. After some clearance testing, I decided to remove the Riddler Differential cover and replace it with the stock cover.
http://i1169.photobucket.com/albums/...t/IMG_2123.jpg
Can anyone please recommend an aftermarket differential cover that will not Rub into the Track Bar ? :confused:

I finally received the "correct" TJ RCV Performance shafts today (Thanks Jeremy!). Installing the shafts was smooth and much easier than I thought.
http://i1169.photobucket.com/albums/...t/IMG_2119.jpg
The axles also came with a can of grease which is a nice touch. Speaking of grease, what is the service interval for greasing the CV axles ?? :confused:

I test fitted the Black Magic Brake Pads, Centric Premium Rotors and Premium Calipers yesterday. They look SWEEEET !! :drool:
http://i1169.photobucket.com/albums/...t/IMG_2124.jpg
It is such a shame that the brakes are going to be covered with my ugly looking wheels.. :(
BIG THANKS to Mr. blaine and Savvyoffroad.com for helping us in this ! :2thumbsup:

karlo 02-28-2012 01:31 AM

Awesome project, dude! Will definitely follow this build thread.:PopCorn:

oalali 02-28-2012 10:17 PM

Quote:

Originally Posted by karlo (Post 13140037)
Awesome project, dude! Will definitely follow this build thread.:PopCorn:

HEHEHE ! :laugh:

I hope that you will enjoy the show.. The fun have just started ! :devil:

Necromancer_tat 03-03-2012 07:17 AM

Nice work so far! I plan on following your build and wishing I had the money to copy you! :rofl:


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