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TX-WJ's build thread.

192K views 512 replies 99 participants last post by  TX-WJ 
#1 · (Edited)
I finally get to start my build thread :p.

So far I have owned 3 WJs, started with a graphite '99 Laredo, loved that color, kept it stock until I sold it; gone but never forgotten.

Then came the silver '03 Laredo, bought it new for $29K :eek: (worst deal I ever made on a car :brickwall), started wrenching on it, 2"BB+UC, MX6s, JKS Disco's, rear Addco, 32 ATs, freedom conversion LOL; was fun while it lasted, lots of mudding, minor dents.



But with the 4.slow and 32s, major loss in power came (was my DD then), started thinking about re-gearing the 30/35, but after pricing the gears/install opted to look for an '04 with the V8; then I found her........

My current (and probably last) WJ is a steel blue pearlcoat V8 4.7 Ltd., what a joy it was stock on the freeway, plenty of power for such a heavy rig; got her on Sept '07 for $13K with 37K mi on the odo; sold the '03 for $10K with 65K mi on it :D.

The build sheet:

Dear David:

Thank you for contacting the Chrysler Customer Assistance Center requesting the build sheet for your 2004 Jeep Grand Cherokee.

According to our records, your vehicle was equipped from the factory
with the following:

*XL Leather Trimmed Bucket Seats
-L5 Taupe
ADE Cold Weather Group
AFFS Luxury Group
AHX Trailer Tow Group IV
APAS Monotone Paint
A82P 4.7L Eng (EVA)/5Spd A/T 5-45Rfe(DGQ)
BAZS 136 Amp Alternator
BC6S 625 Amp Maintenance Free Battery
BRYS Anti-Lock 4-Wheel Disc Brakes
CACS Low Back Bucket Seats
CBWS Highline Door Trim Panel
CFNS Rear 60/40 Folding Seat
CGUS Child Seat Anchor System-LATCH Ready
CG1S Next Gen Multistage Front Air Bags**
CKDS Floor Carpet
CKNS Cargo Compartment Carpet
CKTS Cargo Tie Down Loops
CLES Front & Rear Floor Mats
CLGS Covered Cargo Storage
CLHS Cargo Trim Panel w/Storage Net
CLPS Door Sill Scuff Pads
CSCS Cargo Compartment Cover
CSRS Passenger Assist Handles
CUDS Mini Overhead Console
CUFS Full Length Floor Console
DGES All 5-Speed Automatic Transmissions
DGQ 5-Spd Automatic 545RFE Transmission
DHAS Lock-Up Torque Converter
DHFS Quadra-Trac II On Demand 4WD System
DJJS Dana 30/186MM Front Axle
DMEP 3.73 Axle Ratio
DRKP Dana 44/226MM Rear Axle
EVA 4.7L V8 MPI Engine
GBBS Tinted Windshield Glass
GCBS Front Door Tinted Glass
GEGS Deep Tint Sunscreen Glass
GEPS Flipper Liftgate Glass
GFAS Rear Window Defroster
GNCS Sun Visors w/Illum Vanity Mirrors
GNKS Rear View Auto Dim Mirror
GT3S Power Mirrors, Fold-Away
GWA Power Sunroof
GXMS Remote Keyless Entry
GXXS Sentry Key Theft Deterrent System
HAFS Air Cond ATC w/Dual Zone Control
HGAS Hood Insulation
HGDS Deluxe Insulation Group
I23S Route 23 - CSX, Jessup, MD
JA6S Electroluminescent Instr Cluster
JCBS 120 MPH Primary Speedometer
JHAS Var Intermittent Windshield Wipers
JHBS Rear Window Wiper/Washer
JJBS Dual Note Electric Horns
JJJP 12V Auxiliary Power Outlet
JKAS Locking Glove Box
JKPS 12V Auxiliary Power Outlet
JKYS Power Accessory Delay
JPBS Power Locks
JPDS Power Windows, Driver One-Touch
JRHP Pwr 10 Htd Mem Drvr 6-Way Pass Seats
K4QS STRIPE/BADGE/MOLDING COLOR
LACS Illuminated Entry
LAGS Warning Chime
LAZP Vehicle Information Center
LBBS Courtesy Lamps
LBCS Glove Box Lamp
LCES Rear Courtesy/Reading Lamps
LDBS Cargo Compartment Lamp
LETP Traveler/Mini Trip Computer
LEWS Radio/Driver Seat/Mirrors Memory
LMBS Halogen Headlamps
LMGP Automatic Headlamps
LNJS Fog Lamps
LPSS CHMSL Lamp
LSAS Security Alarm
MDAS Front License Plate Bracket
MFZS Bright Grille
MHAS Black Windshield Moldings
MT2S Trail Rated Badge
MVAS Limited Badge
MVBS Grand Cherokee Badge
MVCS Jeep Badge
MVEP V-8 Badge
MWES Side Roof Rails
MWTS 4X4 Badge
NAS 50 State Emissions
NBGP Federal Tier 2, Bin 9A Emissions
NFPS 20.5 Gallon Fuel Tank
NHFP Power Steering Cooler
NHMS Speed Control
NMHP Hydraulic Engine Cooling
PBQ Steel Blue Pearl Coat
QBQS Steel Blue Pearl Coat
RAAC All Radio Equipped Vehicles
RBP AM/FM Cass/CD Radio w/Changer Ctrl
RCES Infinity Speakers
RDDS Fixed Long Mast Antenna
RDZP Steering Wheel Mounted Audio Ctrls
SBAS Power Rack and Pinion Steering
SCLS Leather Wrapped Steering Wheel
SDAS Normal Duty Suspension
SUAS Tilt Steering Column
TBBS Full Size Spare Tire
TBLS Inside Mounted Spare Tire
TSVS P235/65R17 BSW AS Perf Tires
TZHP Michelin Brand Tires
WF1P 17" Steel Spare Wheel
WGPS 17X7.5 Alum Silver Accent Wheels
WLYC All Steel Wheels
WLZC All Aluminum Wheels
XFHP Class IV Receiver Hitch
XFKP 7 Pin Wiring Harness
XFLP 7 to 4 Pin Wiring Adaptor
XGDP Universal Garage Door Opener
XPFS Protective Coating and Remover
YAAS Build To U S Market Specifications
YGCA 7 Additional Gallons of Gas
ZKGP Spring - Left Front
ZKYP Spring - Left Rear
ZYGP Spring - Right Front
ZYYP Spring - Right Rear
Z6BP GVW/Payload Rating
04HA FAM: LH TRACKING: 20823L06 MY:2003
04IA FAM: LH TRACKING: 20814L05 MY:2003
1AAS U.S. Dealer Retail
135S Zone 35-Washington
2TGA Customer Preferred Package 2TG
28G Customer Preferred Package 28G
3C3A V-8 Bonus Discount
32FA Limited Equipment Discount
39BA New Price Tracking
5I1S WJ-Vehicle Family
5I4S Four Wheel Drive (4WD)/(4X4)
5I8S Left Hand Drive (LHD)
594S Vehicle Order Tracking
6USS Label - U.S. Specifications
621S Maryland State Code
921S Maryland State Code

If I can be of any further assistance please let me know.

Thanks again for your email.

Sincerely,

Senior Staff Representative
Chrysler Customer Assistance Center
Here's the window sticker:





And here she is, in its pure "stock" form (sidesteps installed by the PO :teehee:; as a first mod, those sidesteps have to go).





In with the new, out with the old:



more to come....
 
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6
#41 ·
OK, so pretty close to the present now; in December '08 my club had the last trip for the year over at Cline's, and I must have gotten a little carried away and pushed the dubjay a little too much, taking some lines that I would have normally bypassed; guess the JKs sitting at home gave me tha little extra confidence :brickwall; some resulting carnage took place: Hit the rad support a few times with some bending (no biggie though); wheels got some rockrash :facepalm:; rear driver's fender partly bent/pulled out (the front part of it); but the worst part was I snapped the driver's axle shaft on the D44a with a resulting backslide against a rockwall leading to a big dent to the quarter panel / broken glass....

Since then, the bleeding Jeep has been sitting in the garage awaiting for the neverending little odds and ends to be worked out so I can swap axles and git'er moving again.

The front part of the fender close to the pinch weld got pulled out some and was cutting on the tire a bit:



The rad support: (in this pic it seems I'm really toe'd out, but I am not :dunno:, I checked!)



The worst part :crying: FML!!!:



 
#42 ·
The only good result of the carnage was that I was out of a daily driver; and since no daily driver = no going to work = no money for jeep parts, it was time for a replacement DD.... my new baby, and big part of the reason the WJ project slowed down; now I'm torn between lifting the WJ and tuning the Audi :shhh:.

:wrongforum::D: (Sorry, these are the only pics of the A4 I'll post in this thread). I got my fast back :banana:





 
#43 ·
So you were awing us with the beauty of your WJ just to work up to the point where you beat her up? The poor girl. No more neglecting her. Go fix her up. You've got the axles. Man though, to be serious here, I'd have cried right then and there if I were you. The day I got on a trail, the trees closing in on me, and it was really too tight for a ZJ, maybe okay for a Wrangler, I really scratched up my Jeep. I was feeling bad then. But you did quite a number on yours. I feel for you. It's a terrible thing to see that happen to your baby. How'd you get it home?

Wait, your WJ has the HO V8, doesn't it? That's not fast? I guess not in comparison. But if you an afford that Audi, you really must have a sugar mamma! Why not give me your WJ and the new JK axles since you've a new DD? I'll take them off your hands...
 
#46 ·
Got a chance to work on the Jeep this weekend, and decided to take care of the washer bottle issue as I get ready to move bigger; went ahead and "downgraded" :p to a ZJ bottle, found one off a '98 for like $18 on flebay, came with level sensor and pumps; opted to use the WJ's sensor and pumps so I did not have to mess with the connectors, just plug and play; I made room behind the stock airbox next to the master cylinder, minimal trimming was needed to the ZJ bottle's mounting tabs to clear the hood strut and that vacuum solenoid looking thing (whatever that is :dunno:) which was relocated forward (see pics). Overall, things went pretty well, happy with the result, almost OEM'ish; just took some time to fit things in there so the hood would clear.

Out with the Old: (Ye ole swan).



In with the "older" :D









 
#48 ·
"Older" = better. :D

When are the axles going in?
Dunno, but the parts continue to pile up, waited quite a while for the rear JK swap bracket kit from clayton's, but I'm glad I waited, just got them last week, they look very well designed and pure beef as anticipated, plus I got a pretty good $ deal on them as first costumer for the kit, so can't complain :shhh:. Got the steering for the front almost figured out now, still need to source new pinion yokes........ so hopefully I'll make it to GSW next year :rolleyes:.

 
#50 ·
Already did, APR Stage II, upgraded piston DV and custom PCV fix + catch can, "got boost"? :p

Sorry, you can't have the axles, well, at least not until I'm done playing with them :D.
 
#52 · (Edited)
Started to work on the front axle today; drained diff, pulled brakes, shafts and knuckles; now to get it cleaned up in preparation for:

- Inner sleeves (Off Road Evolution)
- Weld axle tubes to diff housing
- Tack weld u-joint caps on axle shafts (till I can ponny up for chromollys :()
- RockKrawler truss for long axle tube
- Gusset axle C's (ORE's)
- HD relocating track bar bracket (Polyperformance) to match plans for high steer drag link
- Drill out / add insert to pass. knuckle in preparation for high steer
- Upgrade to stronger BJ's (having a hard time finding aftermarket ones)
- HD diff cover
- Swap JK style pinion flange to a U-joint style yoke
- Weld on LCA bracket skids (OREs) and strenghtening inserts (Clayton's)
- Coat knuckles, color TBD.....Red maybe :devil:

Most of the parts for the front axle build already piled up somewhere in the garage :rolleyes:.



 
#54 ·
Yah, me too, I feel bad enough just firing up the WJ in the driveway once a week, I really need to speed up the build and swap these puppies so I can take it out again; it's just been hard the past few months with work, wife expecting our third child, and life in general; at least I got off my butt today and gave things a little boost :eek:.
 
#55 ·
Spent some time working on the front axle this afternoon; cutting and grinding the RK truss and drilling, cleaning the axle tubes to plug weld the ORE sleeves.

Sharp cobalt and cutting oil FTW! :thumbsup:



 
#57 ·
The rear will be a lotta work since all brackets have to be cut and new ones welded, so I decided to start with the front first; plus the rear is under a mountain of heavy boxes with parts :D.
 
#58 ·
OK, so my JK rubi axles have an '08 build date, and AFAIK, the failures noted where the pass. tube fractured was reported on the '07s; but I sure did not want to take any chances, so I got some sleeves for the axle tubes and the RK truss; I went with the OR-Evo's sleeves as they have an outer seal with built in grease zerks.

It was quite tedious drilling all those holes (like 15 total), but otherwise, pretty straightforward job; talk about beef :cool:









 
#62 ·
OK, the front axle is almost done; burned the "C2s" gussets, CA bracket skids and the RK truss; still need to bolt/weld the TB relocating bracket and some bumpstop pads/extra trusses (prolly will wait on those until the axle is mounted so I can measure where and how tall they need to be).

This thing is far from a D60, but it should be significantly stronger with the inner sleeves/truss and gussets; next cut the rear axle brackets and weld the Calyton's axle bracket kit; slap'em Riddler covers, done.

I love my HH210, it almost makes me look like I can weld, almost :welder:; my neighbors hate me, the compressor was on almost all weekend :shhh:.











 
#64 ·
OK, so the front is done; just need to slap a HD cover and mount the knuckles/shafts. Next the rear....... damn it, after seeing those 4 door JKs on 37s :drool:, been pondering the idea of regearing low and running 37s instead :eek:; it never stops. :hahaha:me.

Da pics:









 
#69 · (Edited)
Made some progress this weekend; well not a lot, but progress is progress :p.

Gutted out the rear axle to start working on it, only to find out that the locker sensor plug got messed up during shipping; so I decided to try and fix it since only the plastic part of it broke off, the metal connectors were still intact; I used some plasti dip / liquid tape to insulate it and some self-bonding tape I found in the stash of useless crap one buys from Harbor Freight :rofl:.



FML!!! :brickwall













Then started cutting the brackets..... after being done with one side, the vibes from the angle grinder/cutter were getting to me, so I decided a plasma cutter is my next bday present.







Mocking up the clayton's truss:



I can't wait to have the rear brackets welded and be ready to move on to gears / D-shafts and get the dubjay moving again; getting there slowly but surely :wave:.
 
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