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92 yj build

120K views 611 replies 83 participants last post by  bigsquat 
#1 ·
Well i finally think i have most of the parts and tools to start upgrading the yj. The plan is to change the gearing from 3.54 to 4.10,add aussies front and back.,replace the dana 35 with a 44,slipyoke eliminator,home made posilock,Add another 2" off lift to the existing 4" lift with 6" booms and lowering the spring perches 2".Also going to install a hand throttle,replace the dana 30 wheel joints ,use a cut down front driveline from a xj for the rear of the yj.i need to repaint at least the right front fender or maybe the whole jeep.Ill try to post pics as i go.
 

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#487 ·
we can dream..............
 
#489 ·
i finally started to fab some stronger front spring perches, dam steel is expensive! i used 1/4" wall dom tubing and 2x2x1/4" square tube.
 

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#491 ·
stay tooned!
 

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#492 ·
i had to put the spring hangers on hold. my sending unit went out and i thought i had gas when i didnt! i bought a new pump and sending unit. i didnt want to drop the tank so i cut an access hole. at first i cut the hole to small. it was wide enough but trying to turn the new pump in it wouldnt go. there is a receiver in the tank that the return line goes in that wouldnt line up while twisting the pump. it needs to be straight going in. if i had a body lift it might of worked. after making the hole longer by cutting into the cross brace it worked good. i splice another connecter at the fuel pump for ease of disconect the next time. i couldnt feed the new wires over to the old spot. again a body lift would make it easier. i think after going through the rubicon trail my skid plate has pushed up on the tank and made almost no clearance on top. now to fab a cover for the hole.
__________________
 

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#493 ·
i got the cover done. i used adhesive sealant along with pop rivets to hold the lower flange to the body. i tapped it for #10 machine screws and put some foam sealant tape on it. it is strong.
 

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#495 ·
i have to get them done in the next few days. i have a trail im going to do with up to 20 jeepforum guys next saturday. talk about waiting till the last minute. ill post up the size later. i just went to a shop with my bushing a found a piece that fit it.
 
#496 ·
the round dom is 1-1/4 id and 1-3/4 od. the square tube is 2 in. i decided to add some 2-1/2" to lower the perches a little more so i can cut down the 6" shackles to 5"
 

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#498 ·
once the rockers go on you will piece of mind when you tackle those big boulders
 
#500 ·
i finished the front hangers! since there lower i took the 5" shackles off the back and replaced the 6" ones on the front. i had put the 5" on the back to help correct pinion angle but i need the extra lift so i put the 6" back on and tomorro ill correct the pinion angle with steel shims that will be welded to the perches. i hate aluminum shims,they squish or crack and work loose.

the pic still has the 6" shackels installed, the 5" look much better
 

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#501 ·
i also got the doors painted. not an exact mach but close enough. the bummer is that after i put them on a neighbor's dog jumped up on both doors to say hi to me and scratched both!
 

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#502 ·
i was thinking about painting the chrome rims black. what do you guys think?
 

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#505 ·
i took the jeep wheeling with a bunch of jf members and had a good time for the most part. i had a problem with the right rear brake. the backing plate bent from the rear shoe driving to hard into the top pin. im not sure what caused it but it wasnt the first time its messed up. im thinking about a disc brake converson.
WHEN will i ever get it all dialed in!
 
#506 ·
i did some research and it looks like the best and CHEAPEST options is to use 95-2001 explorer calipers,backiing plate, 2 passenger exploder soft lines, tera flex preload spacer, zj disc's, the spring out of a zj proportional valve. off to the junk yard!
 
#508 ·
maybe if i put ac in! thanks for peeking
 
#509 ·
picked up the stuff from the junk yard($150) the bearings and seals from napa($140) spacers from tera flex($34) $14 was shipping! cable clamps from home depot. its priceir than i thought but im committed to it now.
 

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#511 ·
since you have a dana 35(i think) i would just put the explorer 8.8 in there . i spent as much as buying the whole axle anyway. pick n pull charged me for every bolt ,rivet, brake pad and screw!
 
#512 ·
i pulled the drums and shoes off and installed the disc,s. its time consuming.
i had to elongate the holes in the explorer caliper bracket to fit. i used the bearing and seal retainer plate as a template. i also had to remove just a little off the inside hole of the cherokee disc. i welded some tabs to bolt the flex lines to. after doing one side i found the tera flex spacer was hard to center so on the second side i glued it to the flange plate. doing the swap requires new bearings and seals because you have to remove them to get the tera flex spacer in there. you have to drill the collar and cut the bearing nearly thru to get them off.
i finally got to use my press which i bought 2 years ago.
 

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