My build begins today - when does it end?

**crqflier** · 06-05-2009, 10:00 PM

December 2009 Update:

A little perspective for anyone reading this for the first time. I had zero experience modding a Jeep (or really any other car) myself. The most I had done was new shocks and springs on my M3 plus oil changes, etc. I've got no power tools beyond a drill - no impact, grinder, dremel, welding, etc. And I've got just basic Craftsman hand tools plus whatever special tools I needed to acquire along the way. Hell, I use a bicycle seat post as a breaker bar.... Everything I've done is based on directions and input from folks on JF, Stu, 4x4xplore, and instructions included in whatever parts I've bought. So the bottom line - everything you see in this thread is doable with minimal tools and little experience. If it's in this thread, you can probably do it too.

After deciding earlier this year to once again own a Jeep - had a Cherokee a dozen years ago - I spent a month and a half looking for a stock, unmolested, 1 owner TJ. The only requirements beyond that were AC, 4.0, and full doors. Here's what I found:

It's a 1999 Sport, 5 speed, d35 (yeah, no need to comment) that also came with soft and safari tops, a receiver hitch, and some other little add-ons. No off roading, no accidents, all maintenance records, not a scratch or ding, and 107k miles.

My goal isn't huge. Solid, reliable, moderate+ off road performance. It's not a daily driver, but I really don't want a massive lift/tires and all the complexity that goes along with it - at least not yet.

The first thing I wanted was a little protection. Not having done a thing with TJ's before, I was newbie surprise to see the underside of my Jeep. One massive plate and a sketchy looking gas tank cover/plate. More on both of those later. So I read every review, went on line and bought the following:

Skid Row Steering Box Cover - wow, can't believe where that box is located.
Skid Row Radiator bottom cover - ditto.
Extreme Metal oil pan plate - no plate stock??
Olympic Rock Nerf Bars - the rectangular kind. Decided I didn't want to drill any holes in the body and these bolt on (yup, read the reviews that some regular nerfs rattle).

Didn't realize how long it would take for this to get here - only the oil pan plate has arrive. And so here's my first mod:

Pretty boring I know, but what the hell.

After I get the other stuff on I'm planning on a small lift - either OME or RC2.5. And some 31" MTs - maybe Firestone Destination MT or Dunlp Mud Rover or?? Anything bigger and I think I'd need to get some new wheels since I'm really not up for spacers. And a winch - nothing fancy, probably just the Smitty 8000 lb.

After digging around underneath a little, I've got a couple questions:

These and other bushings look pretty beat - at least it looks like it to me. Do folks do full bushing replacements as a project, or just tackle them as they come? Would a full poly set at every point be crazy stiff?

What about this single big plate? Been reading about a TC drop for the 2.5" lifts and I guess I wasn't expecting to see this. Guess I was thinking there would be a separate TC plate. What happens with the TC drop and the plate?

And how about the seal on the back of the front diff? Mine looks a little moist. Nothing dripping. Normal?

Last question for now. I took the big receiver hitch off - figured it was a low point and adding a bunch of weight. Now I'm re-thinking. Maybe put it back on. It adds protection (at least to the back bumper) and provides a point for a rear tow hook (another surprise for the rookie - not a single rear tow hook to be found, and drilling required to add an after market).

I'll be adding updates as parts arrive. Thanks for reading and any comments/advice would be great.

Mini-Me26 · 06-05-2009, 10:16 PM

The TC drop goes around the six bolts holding the "shovel" (TC skid plate) on. You'll figure out why it's called a shovel after two or three trips. The last looks like a rear pinion seal leak?

victoro · 06-06-2009, 04:29 AM

One of the most important questions? are you married?

mobyjeep · 06-06-2009, 07:52 AM

When does your build end? NEVER!

Kip03TJ · 06-06-2009, 09:07 AM

Quote:

Originally Posted by victoro

One of the most important questions? are you married?

haha I LOL'd

cmoore · 06-06-2009, 10:04 AM

Quote:

Originally Posted by mobyjeep

When does your build end? NEVER!

x2. It ends when your sanity kicks back in, you run out of money, or your girl hides the check book. No matter how much you build it, there will always be something that can be better, redone, repaired, or added on. Good luck with your new addiction...

Greg_Volkman · 06-06-2009, 10:35 AM

I've had my jeep for 8 years....still so much to do. I am never happy with it, and I don't have enough $$ to throw at it to get it to where I want it to be.

Wrangler_91 · 06-06-2009, 10:41 AM

As far as that sway bar bushing i would just leave it for now. Depending on the lift you will installed completly different sway bar links.

And the last picture. That is your pinion seal. You can pick that up at Autozone for like $10. Before you go to replace if you don't already have one I highly suggest you pick up an impact wrench. If you don't want to spend a lot of money HarborFrieght has an electric one for like $40 that works perfect.

BTW nice jeep.

As far as the transfercase skid you have a few different options. Easiest is to do the drop kit when you intall the lift. The drop kit has spacers which go inbetween the skid and the frame andh has longer bolts. THe problem there is you lose precious ground clearance. Another option is a SYE kit which eliminate the factory slip yoke coming out to the transfer case. This is a more intensive job.

If you are planning on putting an aftermarker rear bumper with D ring then I would just out the hitch back on for now as the rear tow point and once you get a new bumper ditch it. If not then you can install a standard tow hook (found at pepboys for like $10) by dilling only one hole, the other is already there.

**Knuckelhead** · 06-06-2009, 12:45 PM

**crqflier** · 06-06-2009, 10:16 PM

Thanks for the comments. I'd read plenty about the TC drop and the SYE option. I just had a far smaller TC skid plate in my head. Had a '89 Trooper and the plate was mayber 12" square only for the TC.

Well, I couldn't wait for more parts to come in, so we went out on a trail today - totally stock (except that oil pan skid) riding on the 30" long trail TA's, solo vehicle. For sure everyone on this forum knows where the story goes from here.

It's hard to tell in the pics, but there's about a 2' ditch off between the right front and back wheel, and about a 3' drop off to the right. It's maybe a 25-30' elevation gain with an underground spring bubbling water in the middle. Yup - stuck. No winch, no jack, no other vehicles seen in the past couple hours. 25 minutes later, after building our some rocks, we made it out and up the trail.

Probably not a big deal with some better tires, a little lift that would have allowed us to drive on the left side of the trail that had some larger boulders. I'm definitely gonna get a winch and a jack. And I think I can also justify some lockers too.....

BTW, my wife has seen this behavior before in the years we've been married. While I've got the green light, I'll keep charging. Took some video and showed how my wheels wouldn't have been spinning out of control had I had all the mods including the lockers. Even reviewed it in slow-mo! She may want me to get it all just so she won't have to watch any more slow-mo video.....

**SuperWade2** · 06-06-2009, 11:03 PM

Quote:

Originally Posted by crqflier

These pics sure take me back...except for the roof rack, OEM Tow hooks, Spare tire cover and Fog lights, that's what my 99 TJ looked like when we drove it off the lot new (in Jan, 99). We got a Auto, but same wheels/color, etc.

Build never ends BTW...

**crqflier** · 06-13-2009, 09:23 PM

Can't believe how long it takes to get parts in. Ordered from 4wd.com with the "free shipping" to the nearest store location. The checkout claims most parts will be there in 1-2 days. Guess I haven't been ordering most parts because it has taken 2 weeks (and still counting) for my parts to arrive.

Still waiting on the Olympic square bars from 4wd and the BFG MT KM2 from Costco (can't believe those are hard to get, especially from the mega store).

So far I've gotten a couple more skids and a tow hook. Wow.....

Notice anything missing from that steering box plate? Gotta look close. Here it is:

Yup. Cross threaded steering box mounting bolt.

Did that yesterday afternoon. Figured, OK no big deal - I'll just cruise down to the dealer and get another (hoping I didn't damage the box too badly). Well, the dealer didn't have the bolt. In fact, the closest one is 500 miles away in San Francisco. That's right. None in San Diego metro or even LA metro. Unbelievable. I guess I thought with maybe 25 million people living in those 2 metro areas, Jeep would be stocking at least 1 of these bolts...

The best part - right now I'm missing a planned weekend of wheeling in Big Bear because I screwed up this bolt.

I'm thinking about starting a thread with idiot stories like this one.

Oh well. It's given me a chance to crawl around under the jeep a bit. Checked all the fluids (records showed everything had been changed within the last 1-5K miles). Sure enough - clean clear diffs, engine. Perfect plugs and wires. Even the air filter is new.

I've also finally decided on the lift. Going to order the OME 2.5. Got sold on also getting the JKS adjustable track bars (front and rear) and the quicker disconnects. Having zero TJ experience, I couldn't imagine how a simple lift was throwing axels off center. Now that I've looked underneath, I get it - simple geometry. Adjustable bars might be overkill with a small lift - who knows. At least it'll be centered.

Big question now is whether to mount the KM2's on my stock wheels and risk the LCA rubbing, or get some Pro Comp 1069's while they're on big sale. (No clue how often the .coms put these things on sale like this).

WhatBump1 · 06-13-2009, 09:26 PM

Jeep build's never end

**Imped** · 06-13-2009, 09:30 PM

Good call on the JKS track bars. It would have been a noticeable shift, believe me. You'll like them very much. And if you're going to want wheels, do it now so you can get the new tires balanced on them initially instead of paying to do it later. I would check around with a couple tire stores to make sure the KM2s still aren't on national backorder. If they are, you're going to need to start looking REALLY hard to see if anyone has extras. I doubt Costco will be able to tell you if they are on backorder, so I'd give Discount Tire a call. They should be able to let you know.

**crqflier** · 06-13-2009, 09:36 PM

Glad to hear the JKS is worth it. Dirk at DPG convinced me.

Costco had 3 MTs in their west coast warehouse and is UPS shipping another from a store in Texas. Gotta hand it to them for going pretty far beyond what they need to do. Even honoring the $75 discount/rebate they were running which is now over. Really don't want the Pro Comps (or any other wheel with less back space than stock) cause I don't really like the looks of the wheel sticking out with 31" inch tires (and I don't want more than 31's). So i'm still debating.