Jeep Enthusiast Forums banner

Louie4's YJ

352K views 3K replies 156 participants last post by  Skerr 
#1 · (Edited)
Well, I figured I would make a "build" thread. I have had my YJ for nearly 10 years and have been doing mods here and there so I won't have a lot of pics of the entire process.

I got my '93 YJ when I turned 16. I paid $1500 at the time which was a steal. I can't find any stock pictures but I have some of the earlier versions.

Some specs as of today:

-3.5" Black Diamond lift springs
-Stock TJ alloy wheels
-Worn out Aurora 31" x 10.5" M/T's (cheap)
-Detroit EZ locker in the rear
-Lock-Right in the front
-Yukon 4.10's front and rear (Yes I still have the D35 and I regeared it:thumbdown:)
-Some kind of hack 'n' tap SYE and a Tom Woods rear driveshaft from a wrecked '95 YJ
-Currie boomerang shackles front and rear
-Herculined Tub


Here's some pics from Tellico when I had 2" double military wrapped springs (complete crap), Liberty all-terrain 30" x 9.5" cheapo tires. I can't remember if I had my rear locker in or not.

I got my SYE from a buddy that worked at the old shop I used to work for.
I had to get the driveshaft shortened because the '95 YJ it came off of was a SOA. Took about 2" out of the center section.


I'm sure a lot of you have had this problem with the rear shock mounts on your Dana 35. I backed into a rock and after a year of on road driving it finally gave out. I replaced them this past April with some generic ones I got from a 4WD shop I rode past. I'll post the new ones up later.
Also, this was the first break. I got my neighbor to weld the piece back on one time and it broke again another year later.


This doesn't show the entire process but it shows some of the gear pattern pics of when I was re-gearing my front and rear axle. I rebuilt both axles replacing all the bearings. I set everything up myself. It was my first gear install and they haven't torn up yet so that's a good sign. I don't know if I would do it again just because of the hassle factor. I don't have all the tools a machine shop has but I have more than the average backyard mechanic. The most important tool I bought was an in-lb torque wrench. I got it from Amazon from a bike shop.


Some of the D30. I had to take the ring gear off to put the locker in. I wasn't thinking and forgot to put it in.



After I re-geared my rpm's went up and vibrations from my front driveshaft were becoming very noticeable on the road. I had originally got a ZJ front driveshaft planning on putting that on the front. I took it to the driveshaft shop and the guy there wouldn't warranty the ZJ one because going to a length of 43" with an O.D. of 1.75" he said it would fail at 3000 rpm's. I was surprised because my stock front driveshaft was that length and I have been running it for a long time. He said he would have to go to a 3" O.D. to warranty it. Well, I ended up spending $50 to have my stock one straightened and balanced. I still have a few vibes but not as bad. Here's some pics of the ZJ front driveshaft and the one I put in.
 

Attachments

See less See more
10
#905 ·
Pretty comfy. They are a hair lower than the stock but not a deal breaker. Still a bit damp from the scrubbing but good.

missed you guys at gulches today. It was muddy and slick! my rig flexes pretty dog gone good. i know this cuz i broke all four fender flares.
Sounds like you did some good. I think me and my buddies are going to hit Gulches for our next ride. Not sure when but I'll post up if we do.
 
#906 ·
Went to Windrock on Sunday and wheeled with some local guys. Real nice guys and I look forward to wheeling with them again.

Today when I got home I found this...dumptastic.





The kicker here is that this is my spare that I have only wheeled with once. I'm going to put some air in it and see where the leak is tomorrow.
 
#910 ·
Doesn't seem like it. Every time I go it's mucky...which I don't care for.

Ill be in gulches this weekend if you're down for a drive to wheel.
I'd like to go but we're celebrating the wife's b-day and going to another birthday party. Take plenty of pics and check out Skip's ride.
 
#911 ·
If I get my new throttle cable in before Saturday I'll see you there. I'm still fixing a list a mile long of things that broke this past weekend.

Nice video Lou, thats exactly how gulches was this past weekend.
 
#919 ·
Like a boss!
Thanks. I get lucky everyone once in a while.

I put a power steering cooler in the jeep yesterday. My power steering fluid was puking out when it got to hot on the trail. The fluid itself was toast so I got this cooler from Pep Boy's for $30. Came with the cooler, hose, and clamps. Not too bad.

Hopefully it helps out.

 
#920 ·
Let us no how this works out, may have to add one myself. I switched to a higher pressure ps pump from a 4.7l WJ and mine has been overflowing on the trail. Given I had way too much in there but I didn't like how hot it was getting. I was forced to use the resevoir attached to the pump instead of my stock yj one which was remote. The outlet hose was way big and couldn't b swapped over. The new pump works like a champ n I can steer locked in 4wd again but I don't want it running too hot. I think I might stop at the junkyard and get a tranny cooler tmrw...
 
#921 ·
Will do.

A trail ride in the Summer will give me an idea. If it doesn't help then I'm only out $30. At least it gives some peace of mind and it can't hurt. I may look into the better pump. The pump and box on my jeep are the OEM ones from 1993 so they may be due.
 
#922 ·
If u decide u want to try the pump, ill mayb do a little write up. Unless u want to swap to the newer intake style 99+ it won't just bolt right on to our yjs. I had to tap all the bolt holes and switch a few fittings but man does it make a difference. I def thinks its getting to hot tho because it flowed over as u said n I'm reading that means its too hot. I think that little cooler could b the ticket. I looked into the psc pump and its only 1500 psi, or stock pump is 1450, and the WJ one is 1950psi. I'm not really sure how the psc one would make much of a difference. I can turn my wheel with just my fingers offroad now, I used to have to muscle it on every turn.
 
#928 ·
I went by the junkyard today and got some little things here and there. I found a return spring and some little attachements for the throttle body. Here is how I setup my linkage for the hand throttle. I tried to find a washer for the adjuster screw but had no luck. I was about to give up until I saw a spark plug gapper in my toolbox. The hole looked to be to the right size and what do you know, it fit perfect. It was even countersunk.



I noticed from other write-ups that there was a return spring on the throttle body and since I didn't have one, I looked for one. Couldn't find the spring on a Jeep so I snagged one off an import and made it work with the little plastic head. I think this will help the hand throttle return. I actually got the handle from an exercise bike I saw in the dumpster in Griffin, GA. I even took a pic and posted a good many pages back. I still need a cable crimp sleeve to hold it but I haven't been to Home Depot. I just tied it in a knot to see how it did. Works pretty good by the way.



I also found a nearly untouched Saab 900. Snagged the sensor housing and will most likely do the Porsche 944 temp switch, eventually.

 
#929 ·
I was about to give up until I saw a spark plug gapper in my toolbox. The hole looked to be to the right size and what do you know, it fit perfect. It was even countersunk.
GENIUS!!!!!!! I just lost about 2 hrs going re-going through your thread. Great vid as well.

:cheers2:

Bernie
 
#931 ·
Thanks! I've done the same with build threads of others...many hours lost.

My Saab housing was rusted pretty badly. I covered it with Jb weld
This one looks to be in good shape based on pics I've seen. It should clean up easily then I'll put some paint on it or some kind of sealer. I just need the sensor and I'll be in good shape.
 
#932 ·
Messed with the jeep today. I got a wild hair and decided to tweak the steering. After JeeperDon said something about a WJ pitman arm and the length and the drop I went to the JY and got one. I had to grind the keys out of the arm but I have a dremel. My current arm is a stock TJ arm. It's 5.5" eye to eye and a 2" drop. The WJ is 6.5" with a 2". I wanted to gain some of my turning radius back and this seemed to be the ticket. Here's a thread on pirate about the arms.

http://www.pirate4x4.com/forum/gene...-start-list-oem-lengths-future-reference.html

I will say the turning has improved. I'll try to post some pics later.
 
#933 ·
Lou, take a look at JGW: Moab 2013 thread. The guys take a trip to Moab and have some really good pictures and videos. I would really like to do this one day, and we can take the woman with us.

On a side note about July 27th: looks like everyone is ago except Kevin. I've also invited my brother in law to bring the red 95 YJ. It's not modified, but maybe he will catch the bug to wheel it more. Have you talked to anyone on JF to see if they want to meet us there?
 
#934 ·
I will check it out. I have not put anything on JF but there is a guy in Knoxville who told me to let him know if we travel because he would like to go. He has a built XJ and a cool guy.

Here's some pics of the pitman arm.





Here are some comparison shots to the stock TJ arm I was running (I got them off Pirate).

 
#936 ·
No clearance issues that I can see. I can turn to the steering stops going left and just barely touches going right. My jeep finally turns like it did before I upgraded the steering.

I also found a castle nut backed out on the drag link TRE on the knuckle. The goferit allowed the TRE to sit low in the arm. When I put the castle nut on it was tightened down past the cotter pin hole so I put a washer on top then a cotter pin. Well it backed out to the washer so I stacked some underneath the castle nut until it was up near the hole. Steering is better and I aligned the wheel straight also.
 
#937 ·
This update is dumb but I parallel parked today and I could really tell the difference in the steering. I am pleased and wish I would have found this arm sooner. I'm thinking a new steering shaft is in order but I may just sleeve my stock on to get some length. The box also has a little play but only side to side but it's also OEM from '93.
 
#938 ·
Louie4 said:
This update is dumb but I parallel parked today and I could really tell the difference in the steering. I am pleased and wish I would have found this arm sooner. I'm thinking a new steering shaft is in order but I may just sleeve my stock on to get some length. The box also has a little play but only side to side but it's also OEM from '93.
I missed it what did you find?
 
#941 ·
Sure. I purchased a Teraflex knuckle from a guy in PA. He also supplied a used drag link that is solid 1.25" rod drilled and tapped. 7/8-18 one end and the stock TRE on the other (pitman). He also made me a 1.25" tie rod (.25" DOM) for use with the same 7/8-18 thread TRE's.

I'm running a sprung under the axle suspension so there will be clearance issues. I drilled out the Teraflex knuckle and installed goferit inserts for the larger TRE's. I flipped the tie rod for ground clearance and flipped the draglink under the knuckle arm for clearance to the frame. I also relocated my extended bumpstops to keep the drag link and frame from contacting on heavy compression.

With the new linkages and knuckle my dropped pitman arm was too low and running into the tie rod. I initially ran a shorty billet steel arm but lost a lot of turning radius. To get a longer arm I bought a Parts Mike steering box relocation bracket that moves the box forward 1" and inward 1/2". I eventually went to a TJ arm (2" drop, 5.5") with the new pitman to tie rod clearance but wasn't satisfied. Finally, JeeperDon mentioned the WJ arm being 6.5" long with the same 2" drop. I measured clearance to the tie rod and it just works. So I got to the JY, found the arm, and grinded the keys out and installed it to my liking.

Works great!
 
#942 ·
Well I don't have any real updates. However, my buddies and I are wheeling at Adventure Off Road Park in TN July 26-28th. Should be a good ride and hopefully the park is fun.

I have thought about my future plans for the jeep and I figured I'd make a list on here to remember and stay on track.

SOA: I have a need for more articulation out of my jeep. I want to get some 0" lift springs or stock rears, maybe even Waggy springs. I already have the steering in place to make this possible. I would just flip my drag link to the top of the Tera flex arm. I will need a traction bar and a good way to mount it. I've seen many build threads about them so I will just have to do the research.

Dual Batteries: I am finding that I use a lot of juice when wheeling and just driving. I have the Taurus fan and I will wear the battery out with the winch. I also told my wife I would fix the A/C for her at some point. That means the fan will be running as well as the compressor and blower motor. So I think it's a must. I have been reading up on a few write-ups.

High amp alternator: I figure this will get lumped into the dual batteries. My current alternator is from a 1990 Cherokee that I swapped in after mine bit the dust. It's only a matter of time until this one goes.

35" x 12.50 Tires: I'm tired of 33's. They get the job done but I bash too many rocks.

High clearance skid: May get the UCF and get the one for better clearance. I already have a 1" body lift so that's a plus.

These upgrades probably won't happen until I'm finished with my masters this December. But once I'm done and have a full-time engineering job I will be acquiring a better welder and all the parts needed. I can currently make the dual battery tray so that might be the first thing I do.
 
#1,007 ·
Just got caught up on the last year! :thumbsup:

Sounds like we might be on the same page... Thinking SOA next year / winter build. Bought a new Harley last Nov and all the $$ went to that,.

You'll love the Alternator mod, GC works and dual batts... Did that all last year in my frame swap...

Belly up in the plans, but not sure how the shaft brake will work. Might be to tight to the tub...

FYI. I did the Durango box last year, and haven't had any over heating issues with the ps to the best of my knowledge....

Keep it going !!!
 
#945 ·
Louie4 said:
Well I don't have any real updates. However, my buddies and I are wheeling at Adventure Off Road Park in TN July 26-28th. Should be a good ride and hopefully the park is fun.

I have thought about my future plans for the jeep and I figured I'd make a list on here to remember and stay on track.

SOA: I have a need for more articulation out of my jeep. I want to get some 0" lift springs or stock rears, maybe even Waggy springs. I already have the steering in place to make this possible. I would just flip my drag link to the top of the Tera flex arm. I will need a traction bar and a good way to mount it. I've seen many build threads about them so I will just have to do the research.

Dual Batteries: I am finding that I use a lot of juice when wheeling and just driving. I have the Taurus fan and I will wear the battery out with the winch. I also told my wife I would fix the A/C for her at some point. That means the fan will be running as well as the compressor and blower motor. So I think it's a must. I have been reading up on a few write-ups.

High amp alternator: I figure this will get lumped into the dual batteries. My current alternator is from a 1990 Cherokee that I swapped in after mine bit the dust. It's only a matter of time until this one goes.

35" x 12.50 Tires: I'm tired of 33's. They get the job done but I bash too many rocks.

High clearance skid: May get the UCF and get the one for better clearance. I already have a 1" body lift so that's a plus.

These upgrades probably won't happen until I'm finished with my masters this December. But once I'm done and have a full-time engineering job I will be acquiring a better welder and all the parts needed. I can currently make the dual battery tray so that might be the first thing I do.
I'll help you with the spring over and traction bar. I've been thinking about the dual batteries, I'm guessing your going to stay 12 volt but have them in parallel? Dual batteries and HO alternator would be a beast. 35's and a high clearance skid will help tremendously.
 
#947 ·
Yes. I don't think the stock electronics would like the 24V system. I may have to take you up on the help. I may need it.

X2.

Let me know if i can help by answering any questions you have
Thanks. I will most likely send you some questions as this starts to unfold.

I guess I will be on the lookout for stock springs...possibly waggy's.
 
Top