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Louie4's YJ

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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.

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Discussion Starter · #2,364 ·
That's what I'll do, just flip the bolt. Never had an interference issue with my OEM box, but this one has a bigger bore.

Got my rebuild kit today.


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Discussion Starter · #2,366 ·
Yes. The delivery box was 8”x8”x6” and I gave it to my wife because I thought it was hers. I was surprised to find out it was the kit.

I pulled the ball out of the u-joint holder but could not get the little race out. I broke two chisels trying to remove it. Still haven’t gotten it out.


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pulled the ball out of the u-joint holder but could not get the little race out. I broke two chisels trying to remove it. Still haven't gotten it out
I think the ball yoke is available as a complete? A few more bucks maybe but it would cure it, right?

Pull out the welder and run a QUICK bead around the inside about a third of the circumference. It will shrink and come out. Gotta be quick so it doesn't penetrate cuz then, well, it ain't coming out, is it?
 

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Discussion Starter · #2,368 ·
I think the ball yoke is available as a complete? A few more bucks maybe but it would cure it, right?

Pull out the welder and run a QUICK bead around the inside about a third of the circumference. It will shrink and come out. Gotta be quick so it doesn't penetrate cuz then, well, it ain't coming out, is it?
A new yoke and centering ball is about $92 + tax. last time I bought a new one (Spicer) it was maybe $45. The rebuild kit is $30 and it's a Spicer part. I thought it would be simple but alas...it's not. I may try putting bead on it.
 

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Discussion Starter · #2,369 ·
Got my rear springs on and I'm pleasantly surprised. I thought they would be really tall but it seems reasonable and they will settle. Just need to do the front now and rebuild my rear driveshaft.




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Discussion Starter · #2,370 ·
I got three springs on until I got to the drivers side. The holes were just too wallered out and oblong. The 9/16" bolt moves way too much. Luckily I have a spare spring hanger ready to go on…I just need to cut the old one off and weld new on.



The side shot is deceiving because the hole is pretty large but the other hole mask it.

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Discussion Starter · #2,373 ·
Good eye.

It was used to widen the other spring hangers. The poly bushings are about 3/16” thicker on each side versus the OEM spring eyes. I went from OEM bastard packs to the RE with poly bushings.

Links are a dream when I have time…I don’t have time. I feel like Im spending time at my actual house with my jeep like a mistress :)

And then return to my rental to my family.


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Discussion Starter · #2,375 ·
My jeep is still sitting at my house house but I hope to move back in soon and put my last leaf spring and hanger on.



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Discussion Starter · #2,376 · (Edited)
I figured I should put up an update. I moved back into my house after 6 months of living elsewhere due to water damage back in July. I've been back in since right before the new year and it's great being back in my own home. With that said, I take about an hour to cut and grind on the jeep. I'm still working on getting my driver front spring hanger cut all the way off so I can weld on my new one. I have the new one from years back replacing another. I forgot how much of a pain in the *** it is to cut the old spring hangers off. Once I get it back on, I can put my last new RE SOA spring on, put my rear driveshaft in, bleed the brakes and get it on the road a little. Once I get it back driving I need to park it again and get another engine to replace my oh so very tired 4.0. I found some on FB marketplace for less than $1k but I do want it to be a new one and even better would be a Golem but that's in the $6k range.

I'm still trying to figure out what to do. Its hard to justify the stroker given how much I actually drive it, but it sure would be nice to have when I do take it out. I'll try to get a pic later today of my "progress".

Also...Go Dawgs!

Not only did my home state get a World Series, my alma mater won the national championship as well.
 

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I figured I should put up an update. I moved back into my house after 6 months of living elsewhere due to water damage back in July. I've been back in since right before the new year and it's great being back in my own home. With that said, I take about an hour to cut and grind on the jeep. I'm still working on getting my driver front spring hanger cut all the way off so I can weld on my new one. I have the new one from years back replacing another. I forgot how much of a pain in the *** it is to cut the old spring hangers off. Once I get it back on, I can put my last new RE SOA spring on, put my rear driveshaft in, bleed the brakes and get it on the road a little. Once I get it back driving I need to park it again and get another engine to replace my oh so very tired 4.0. I found some on FB marketplace for less than $1k but I do want it to be a new one and even better would be a Golem but that's in the $6k range.

I'm still trying to figure out what to do. Its hard to justify the stroker given how much I actually drive it, but it sure would be nice to have when I do take it out. I'll try to get a pic later today of my "progress".

Also...Go Dawgs!

Not only did my home state get a World Series, my alma mater won the national championship as well.
First off congrats on being back in your home.

The engine decision is a tough one. if you got a used one, it would make the most sense toe rebuild it prior to tossing it in. but if you do that then get one already rebuilt. but then a bit more just get a stroker. It does make sense to stick with either the 4.0 or get a stroker, "easier" installs. A V8 swap could/should be cheaper but then you have to do a lot of fitment modifications, and it might not even be what you are looking for.

Definitely the year for Georgia, well in two sports.
 

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Discussion Starter · #2,378 ·
Thanks! I will probably peruse the interwebs for a low mileage 4.0L and also look for a new one. I need to see what my bonus looks like also, since that can impact my decision.
 

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Hate to say it.. LS is probably going to give you the most bang for your buck.

Easy swap, mods are endless, and tons and tons of support out on the inter webs for doing the job.

My fingers are crossed that your bonus is way more then you expect and a Diesel swap is in on the way!!
 
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