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Unread 02-02-2013, 05:34 PM   #1
bty34
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2000 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ithaca, NY
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Tax season wrangler rebuild

The focal point of this is going to be a frame swap on a TJ. I will be attempting to do the bulk of the work prior to April 16th (my wife is an accountant)

A little backstory, purchased the Jeep back in 2004, was a salvage rebuild.



Over the last 8 years, the Jeep has made it to this. If anyone has any questions about anything in between, let me know, but most of it is normal stuff so I will skip it for now.



Around a year ago I noticed a soft spot in the frame by the rear crossmember. Since the frame is already a little twisted, I figured it was best just to swap it out.

Purchased a frame from Davey's Jeeps. Not sure where it was from, but it has no rust. A little red dirt came out when I washed it the first time.



Plans are:
Swap frame
Raise body mounts 1.25"
Change shock mounting
Detroit in front
Poly Perf cage
Mastercraft seats
Savvy Under Armor if funds allow

While it is apart I'll put some parts of for sale, if they sell plans will change. If not, they will go back on.

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Unread 02-02-2013, 05:45 PM   #2
bty34
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Frame prep

I got the frame inside and started working on it.




Plugged a couple of extra holes.










Cut off the rear crossmember.












Started moving center body mounts










Cut off rear coil buckets



Little sandblasting.




Primed the bare spots




Coated with Rust-Oleum gloss black




Last edited by bty34; 02-03-2013 at 12:49 PM.. Reason: Added pictures
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Unread 02-02-2013, 07:00 PM   #3
Moezer
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looks good why did u cut the back cross member?
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Unread 02-03-2013, 03:54 PM   #4
bty34
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Quote:
Originally Posted by Moezer View Post
looks good why did u cut the back cross member?
I'm adding a body lift, and since I already drag the rear bumper more than I like to, I moved the crossmember rather than using lift pucks. I'll be using 3 rather than the normal 11. I thought about moving the crossmember the shocks bolt to, but it doesn't seem like it would gain me much.
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Unread 02-03-2013, 08:05 PM   #5
Moezer
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I see our still going to reinforce it?
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Unread 02-03-2013, 09:08 PM   #6
contdevelop
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This should be good!
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Unread 02-03-2013, 10:08 PM   #7
kyle_craig
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Nice build. I like the frame mods. How do you like your TnT fenders?
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Unread 02-04-2013, 10:30 AM   #8
dayriesw
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Those front fenders look great with the color match. Good idea about the body lift, without the body lift.
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Unread 02-04-2013, 05:05 PM   #9
bty34
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Quote:
Originally Posted by kyle_craig View Post
Nice build. I like the frame mods. How do you like your TnT fenders?
Back when I bought them (2009) there weren't all that many options for full replacement fenders. If I was doing it again I would look elsewhere, probably Poison Spider.

Main reasons are:
They are wide in the front since they don't taper and I have the 4.5" flare version. I occasionally catch the corner on the trail.
It's difficult to keep the rust at bay. There is a section in the middle where two pieces of sheet metal overlap, and the joint with the tube. I would expect it if the Jeep was a daily driver, but anymore it spends winters in the barn. This is the main reason I like the Poison Spider.
Lastly, I feel like they didn't put much thought into the inner fender. The design is simple, but gives up more room than most.

I'd like to replace them some day, but they are pretty far down the list, so it will be awhile.
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Unread 02-06-2013, 12:53 PM   #10
MG_salsa
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sweet!
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Unread 02-06-2013, 01:28 PM   #11
flopp00
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I need to do this i will be watching this very closely
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Unread 02-10-2013, 01:32 PM   #12
bty34
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Got the Jeep out of the barn. Discovered it is worthless in the snow with only 2wd. I had pulled the front driveshaft this fall due to some trail damage.




In the shop waiting.




Took some measurements

Gas tank skid



Rear crossmember



Frame rail and center skid



Front frame rail




Pulled the rear axle. The ebrake cables fought with me a little bit, but otherwise went fairly well.



Needs a little attention



So do the arms




Pulled the joints on the uppers apart. I was surprised to find the bushings were one piece rather than split. Currie sells a rebuild kit for the joint, so I guess you can change the bushing if you ever need to.

http://www.currieenterprises.com/ces...t.aspx?id=3859



Ready to go back in



Pulled the lowers apart, wiped the bushings down and put a thin coat of grease on them and put them back together. The paint is drying on them now.


Cut of the lower shock mounts, they were looking a little rough.



Axle cleaned up and primed



Started bending brake lines





New brake hose and vent line



New trac bar bracket




All done






Last edited by bty34; 02-14-2013 at 06:25 PM.. Reason: Added pictures and notes
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Unread 02-24-2013, 05:14 PM   #13
bty34
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Front axle pulled




It looks like I could use some more clearance under the axle








Had some rust on the stock shock mount



and some debris underneath




All cleaned up




New Currie mounts






I also cut of the Currie mini skids, bent them back into shape and aded them to the new mounts.


Last edited by bty34; 03-02-2013 at 05:05 PM.. Reason: updates
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Unread 03-04-2013, 07:18 PM   #14
bty34
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Overall, my modified stock cover has been holding up pretty well to the abuse



But it is starting to lose some material on the bottom edge. The part that had me a little nervous was the matching gouges in the diff.




I went and grabbed an old LP30 housing I had laying around. I pulled it out a junkyard back during cash for clunkers to get the 3.73 and up carrier



Stole the cover off it and then cut it up for scrap. Saved the cover, cover bolts, and trackbar/ coil mount. If anyone was curious the tube size on a TJ LP30...






I sandblasted the cover before I realized HP and LP covers are not the same.



I put the cover over the housing anyway and noticed my housing is not missing as much material as I originally thought.



I'm leaning towards reworking the cover I was using. I also noticed some damage to my trackbar bracket. I had one situation where I bent the draglink enough that the tierod rubbed the trackbar bolt and allowed it to loosen. I bent the draglink back and replaced the trackbar bolt and it never gave me any trouble, but the damage to the bracket was hidden the the brace I have over top for the ram assist. I may clean up the bracket on the junk housing and see what I have to work with.



Put that on the back burner for now and moved on to installing the detroit. Pulled the open carrier and swapped the ring gear over.

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Unread 03-09-2013, 04:04 PM   #15
bty34
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Detroit is in. Actually found my notes from when I installed the gears 3 years ago. Went pretty smoothly. I've found it is a little easier when you take your time and have a comfortable working position. Doing differential work with the axle still under the vehicle and it only up on jackstands makes it a lot more frustrating.




Shock tabs for the front lower mounts came from Ruffstuff.




Started back on the cover. I cut some pieces off the LP cover I had blasted.



I didn't have a great way to hold the cover while I was welding, so I cut the tubes of the junk housing I had in the scrap pile.



All welded up with new additions



Painted up and bolted on

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