2004 WJ TRL HWK Build - Trails and Camping - Page 4 - JeepForum.com
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post #46 of 70 Old 04-02-2019, 01:53 PM Thread Starter
jayheats
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Finally finished up some touch ups and rust treatment areas...







Finally got my jeep looking decent



2004 WJ TRL HWK Edition
Upcountry, 265/65R17in Tires, JK Rubicon Wheels
F/R Vari-lock
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post #47 of 70 Old 04-11-2019, 06:11 AM
DVLDOG
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Lot of work done! Looks great.


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2004 GC Limited, Graphite Metallic, 4.7 L
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post #48 of 70 Old 04-11-2019, 08:00 PM Thread Starter
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Added a drain plug in the Transmission pan, scraped off the paper filter gasket I put on a week ago and reinstalled a Few-pro... Lesson learned.


2004 WJ TRL HWK Edition
Upcountry, 265/65R17in Tires, JK Rubicon Wheels
F/R Vari-lock
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post #49 of 70 Old 04-11-2019, 10:00 PM
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Dude, this thread is an inspiration!
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post #50 of 70 Old 04-12-2019, 09:01 AM
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Awesome! Is there a write up to add the drain plug in the transmission pan?

2004 GC Limited, Graphite Metallic, 4.7 L
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post #51 of 70 Old 04-12-2019, 10:40 AM Thread Starter
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Quote:
Originally Posted by DVLDOG View Post
Awesome! Is there a write up to add the drain plug in the transmission pan?
Sorry, I didn't do a write up. I just used the Dorman HELP! 65128 Transmission Drain Plug Kit. Not really much to do a writeup on it since it only involves drilling a 1/2 hole.

Now before you use that kit... go and read the amazon reviews so you are aware of the drawbacks. The bad reviews are real, so know how to counter those faults while you are installing it. I used RTV on the plastic washers and tunnel bolt, and plumbers tape on the drain plug bolt.

I also pointed my drain toward the back (mounting it on a vertical side of the pan) so that it would be less likely for a rock to hit it. If you do mount it on the side of the pan, make sure you don't put it in a spot that would end up touching something on the inside (like tranny solenoids, etc) Good luck!

AS I WROTE THIS I JUST REALIZED SOMETHING!!! .. I forgot to put the magnet back in there.... oh crap!

2004 WJ TRL HWK Edition
Upcountry, 265/65R17in Tires, JK Rubicon Wheels
F/R Vari-lock

Last edited by jayheats; 04-12-2019 at 10:43 AM. Reason: I'm an idiot
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post #52 of 70 Old 04-12-2019, 10:42 AM
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Thanks Jay! I just purchased a Fumoto valve for the oil pan, was wondering how to also help make the trans change easier also. Thanks for all the info!
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2004 GC Limited, Graphite Metallic, 4.7 L
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post #53 of 70 Old 04-13-2019, 10:42 AM
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Jus a late entry.. many of you already know, Iím a 247 Quadra Drive advocate.
Iíve driven mine through thick mud, and mud on hills, to rock hills all in Quadra Drive. Granted, itís not for every situation, but thatís why you have 4WD low!


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post #54 of 70 Old 04-15-2019, 07:56 AM
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Quote:
Originally Posted by jayheats View Post
AS I WROTE THIS I JUST REALIZED SOMETHING!!! .. I forgot to put the magnet back in there.... oh crap!
Just get an old speaker magnet or something close in size. Then put the magnet on the outside of the pan. It'll work until you get to a point in changing the fluid again.
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post #55 of 70 Old 04-15-2019, 10:00 AM
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Quote:
Originally Posted by 99sajeep View Post
Just get an old speaker magnet or something close in size. Then put the magnet on the outside of the pan. It'll work until you get to a point in changing the fluid again.


Thatís a super trick! Iím going to store that in my mental data banks!

You can get those super strong magnets at Harbor Freight. Strong enough to not fall off under any circumstances, Strong enough to pull particles out.

Actually, that might be a good idea to use all the time. It will attract particles to a smooth part of the pan. So you can just wipe the area clean easily. Those internal magnets can be a pain to clean...


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post #56 of 70 Old 04-17-2019, 04:28 PM Thread Starter
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I finished my bumper modification and shallow fogs lights.

Here is how much I took off.


Next I use the fog light bracket for a straight edge and mark parallel to the back of the fog two center lines. This is where the main bolt will line up later on and I want it to be straight.



I cut off the bumper edge and then cut the back off the fog light housing.



Here is the new mounting solution I used for these new fog lights. They are pretty thin like hockey pucks. They are brighter than the factory OEM fogs and thin, so that my wheel won't touch them.



Here is the fog lights from the front with the covers.



Finally finished my inner wheel plastic. My old ones had holes rubbed in the front from the wheel touching, so I got some replacements.

On my front bumper, I took the pieces and bondoed it back inside so I would have a trim piece to mount the liner to. I also used a cutting wheel and trimmed the back pinch seam down to the spot weld, then hammered the pinch seam over in the thinner areas. In the front wheel well, I trimmed off some of upper metal as well, to the bolt stud. Relocated my horns and the washer bottle. It may not look much different (but that was the goal, to gain clearance while retaining the stock wheel well plastic liners)... so all the high metal points that the tire would normally touch while flexing have been removed. Three new holes have been drilled on each side for repositioning the plastic liner and it fits further up into the fender. Now she is all back together.








Final result was new wheel plastic and a larger opening for flexing my 31" tires




2004 WJ TRL HWK Edition
Upcountry, 265/65R17in Tires, JK Rubicon Wheels
F/R Vari-lock
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post #57 of 70 Old 04-18-2019, 07:27 AM Thread Starter
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Flex Test Day

Now that the front fenders wells are all done, it was time to test the articulation. I crossed my fingers that my trimming efforts were of good use so I disconnected the front sway bar and flexed it out. The end result made me smile, no touching while flexing and turning.

My wife kinda l laughed when I tried to explain everything I did to get a 31" tire with only an upcountry lift to flex into the wheel well. When she looked in the wheel well... she said everything looked normal (like it was stock). Yet I have trimmed about 2inches in the front and and inch in the back. Cut bumpers, reattached the bumper lip with bondo, relocated washer bottle, moved the horns, upgraded to thinner fog lights, trimmed metal, hammered pinch seams and repainted the whole front bumper.

I don't see too many WJ that can flex a 31" and still have it wheel well that's looking clean... let alone has a inner wheel well plastic still intact.














2004 WJ TRL HWK Edition
Upcountry, 265/65R17in Tires, JK Rubicon Wheels
F/R Vari-lock
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post #58 of 70 Old 04-20-2019, 08:54 PM Thread Starter
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My main focus for this rig was retain stock ride level (upcountry lift springs came stock) and make it more offroad capable (including articulation for a decent size tire).

Lets see, the qualifications for the TrailHawk Badge;
  • Tow hooks
  • Upgraded Jeep wheels
  • All-terrain tires
  • Skid Plates
  • Trail Rated 4X4 drivetrain
  • Most capable offroad of the various trim selections

TRAILHAWK badge earned!



Now it is time for some trails and camping...
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2004 WJ TRL HWK Edition
Upcountry, 265/65R17in Tires, JK Rubicon Wheels
F/R Vari-lock
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post #59 of 70 Old 05-20-2019, 08:04 AM Thread Starter
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Wj 242 WJ Transfer Case swap

Well a late winter and long rainy spring has kept my favorite camping spots deep in snow and mud... In the meantime I decided to do one more upgrade.

I have a 2004 WJ V8 with the 247 Transfer Case right now and I just finished putting back together a 242 WJ case following this guys video.


So far I have completed these steps:

1) Removed the short I6 242WJ input shaft and replace it with the longer 247 input shaft from the v8.

2) Removed the front output crappy rezeppa yoke from the I6 242 case and replaced it with the V8 front output yoke.

3) Grabbed the I6 rear yoke and combined it with the v8 rear drive shaft.

4) Replaced 2 u-joints

5) Re-installed my V8 front double cardan shaft.

6) Installed the shifter from the I6 WJ.


Notice in the picture, the front input shaft is now longer and the front output has been swapped.


242wj yoke on the V8 rear drive shaft.. ends up being the perfect length.


242WJ case installed with a I6 rear yoke and original V8 rear driveline


New Shifter installed.

Overall, not too hard of a project... just a bit time consuming.

2004 WJ TRL HWK Edition
Upcountry, 265/65R17in Tires, JK Rubicon Wheels
F/R Vari-lock
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post #60 of 70 Old 05-21-2019, 10:23 AM
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The dark silver emblems I have on my jeep are from a new model trail hawk wk2
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