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Unread 06-30-2014, 09:28 PM   #76
dlundblad
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Dang Tom! I had no idea you were putting this beast together. It is looking exceptionally well. Great job on all the welds and detailed pics.

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Unread 07-15-2014, 07:27 PM   #77
skain8
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Quote:
Originally Posted by fast540 View Post
Mr skain, nice to see your rig together. Bet you won't be breaking axles anytime soon
Thank you, sir. Doubt it!

Quote:
Originally Posted by dlundblad View Post
Dang Tom! I had no idea you were putting this beast together. It is looking exceptionally well. Great job on all the welds and detailed pics.
Thank you as well, sir.

Quote:
Originally Posted by thejeep88 View Post
You gonna have this beast at the all breeds jeep show in a few weeks?
Doesn't look like the jeep will be there, but I plan to. Look for EndlessMtnFab!
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 07-15-2014, 07:33 PM   #78
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9" drain

Added a drain to the 9". Props to StrokedWJ for the suggestion and the pic earlier in the thread. Here's what we came up with for max function and low-profile protection -- you can see it is recessed, reinforced (just a tad ), and a magnet was jb welded to the to inside plug to catch any metal. Notice the rear truss burn marks on pic #4?

drain-1.jpg

drain-2.jpg

drain-3.jpg

9paint.3rd-member-drain.jpg
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 07-16-2014, 12:13 PM   #79
StrokedWJ
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^ Nice work! That came out really nice!
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Unread 07-21-2014, 07:05 PM   #80
skain8
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Front & rear swaybar

Front swaybar is retained. Creativity was needed for the front swaybar links in order to achieve optimal angle (i.e. parallel with the lower control arm) while avoiding any interference of the front steering or suspension. Here is the driver's side design. Passenger is similar, and was much easier since no steering links to contend with. WJ style JKS disco's are used (open loops top/bottom). The pics are a bit deceiving -- there is plenty of clearance between the link arm mount and the trackbar.

front-swaybar-link.jpg

front-swaybar-link-2.jpg



Rear swaybar is mounted to the truss. If the gas tank was raised, it could be mounted much higher up, but as it currently sits, there is no clearance issues with the stock tank skid. Rear swaybar links are JKS disco's (not pictured) -- not for disconnect function, but moreso for flex. I like the stock rear swaybar connected.

rear-sb-bushing-view.jpg

rear-sb.jpg

rear-sb-side-angle-2.jpg


In this pic, you can also see the rear shock mount. The goal was to position the shock for optimal dampening (i.e. as close to perpendicular to the ground as we could get, within reason given design limitations).

rear-shock-swaybar-combo.jpg
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 07-21-2014, 07:13 PM   #81
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Quote:
Originally Posted by StrokedWJ View Post
^ Nice work! That came out really nice!
Thanks.

Provided some more content re: ABS, speedometer and brakes (prop valve) early in thread at post #5.
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 08-26-2014, 07:53 PM   #82
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POR, primer & paint on the 9"

Light dusting etch primer after bare metal was POR'd:

9-primer-front-view.jpg

9-primer-rear-view.jpg

1st coat topcoat:

9-black-topcoat-rear-view.jpg
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 09-02-2014, 08:13 AM   #83
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PM's replied to. If you have a specific question, please just post it and I'll do my best to answer.

Also, I added some additional info regarding the speedometer in post #5. BTW, anyone have a 39 tooth speedo gear laying around?

Cheers.
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 09-02-2014, 11:00 AM   #84
mtnmarc
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Glad to see you figured out the speedo wiring man!

It was a pain when I did it cuz not a lot of true info was out on the interweb. A few people had ideas, but nothing really to follow. And that was a good thing to say that Chrysler has different colors for wires, because I ran into that issue first hand. Haha. Where are the full widths and coilovers

And with the speedo gear, mine with 5.38s and 37s is dead on with a 41 tooth I believe.
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Unread 09-23-2014, 06:35 PM   #85
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231 speedo

As Mtnmarc wrote above, the speedo wiring was a bit of a struggle. I revised the thread a bit for that section (post #5), hopefully for others to avoid our headaches. Here is the 231 with the speedo port, which was previously sealed off:

231-open-port.jpg


And here is the finished product with the speedo gear in place and wiring run back along the rail to the driver rear speed signal wiring:

231-wiring.jpg
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 09-23-2014, 06:41 PM   #86
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D44 updates

Here is the D44 w/primer and ready for paint:

d44-primer.jpg

D44 back under the truck. Picture of the driver spindle, hub, lockout assembly. Note: when using manual lockouts such as Warn, the drive slug springs are not used (shown in picture for illustrative purposes only).

driver-spindle.jpg

driver-spindle-2.jpg

hub-1.jpg

hub-2.jpg

warn-lockout-complete.jpg
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 09-23-2014, 06:44 PM   #87
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9" assembly

9" under the truck. Pic of the rear drums. Salvage what you can from the donor axle, but drum rebuild kits are cheap, so spend a bit for peace of mind and ease of install.

rear-drum-complete-1-.jpg

More pics to follow...
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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Unread 09-23-2014, 08:05 PM   #88
gtg413i
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Very nice. Can't wait to see this baby showing up some wranglers.
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Unread 09-23-2014, 08:22 PM   #89
wvracer821
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really nice job on the swap, i cant wait to see this thing on the trail. ive been taking notes for when swap the 60 and 10.25 into my turd
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Unread 09-24-2014, 06:56 AM   #90
skain8
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Quote:
Originally Posted by gtg413i View Post
Very nice. Can't wait to see this baby showing up some wranglers.
Quote:
Originally Posted by wvracer821 View Post
really nice job on the swap, i cant wait to see this thing on the trail. ive been taking notes for when swap the 60 and 10.25 into my turd
Thanks, fellas. If you have any specific questions, just ask. If I don't know, I know someone that will.
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
Half-Ton axle swap guide


*looking to buy 3" springs or swap my 4.5" springs for your 3" springs -- PM me*
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