[cccj]

It drives again! Now much quieter than the old worn out 8.8 with the new 4.10 r&p in the high pinion dana 60 rear. A little more unpredictable now with a Detroit locker, but it should work great offroad.

I've got TJ rear brakes on it which work and feel great. I have removed the stock parking brake assembly and grounded the wire to bypass the light, but I still have a 'Brake' light on the dash if the proportioning valve sensor is connected. I disconnected the sensor to make it go away.

 

[cccj]

I’m showing restraint when it comes to cutting out the body, so I made some rear bump stops to keep the 37s out of the flares.

 

[lovett86]

Nice

 

[brian674]

Pretty sick Jeep Bro!

 

[cccj]

Took the YJ to River Rock ORV park (Milledgeville, GA) over this weekend. I took it easy at times on the dana30 front but definitely tested it at the same time.

Early on I broke the drivers shackle hanger off the frame. I blame it on poor design with the front shackles on approach, but also driver error.

I welded it back together and added a strap wrapped around the bushing mount.

 

[lovett86]

Nice

 

[cccj]

I sold my street tires and wheels (bronze Method and 315/70R17 Cooper AT3) so I was stuck driving on the 37x12.50r15 Super Swamper Trxus, which don't roll great even with 10oz of beads. I want to drive the YJ on my 40-mile commute to work, so I installed the Toyos from my TJ. It's convenient having matching bolt pattern (5x5.5) across the fleet.

40x13.50r17 Toyo Open Country MT
17x9 Sidetracked Offroad MG aluminum

Now with the 40s it will cruise at 70mph at 2500rpm in 4th gear.

Drag link took a little bend last weekend so the wheel isn't straight anymore.

 

[cccj]

Took the YJ to River Rock again with a local club of mostly JKs. It’s definitely at a disadvantage wheelbase to the JKUs, but I try to make up for it with horsepower.

Again the drivetrain held up despite abuse, but it time for a front locker. I’m not putting any money into this dana 30, so I’m starting the front axle swap next week.

 

[cccj]

This front axle swap started today at the exhaust.

The plan is to simplify the dual exhaust into a single tailpipe. This will get the current tailpipes out of the wheelwells and gain some space in front of the axle for upper links down the road.

 

[cccj]

Next I pulled the 231 transfer case.

The replacement tcase will be a 231/300 doubler combo recycled from a previous build. I don’t necessarily need an additional low range but I need the Dana 300 and why not.

 

[cccj]

Today I struggled through clocking the tcase where I want it. I pulled apart the 231 kit and rotated it to use the stock YJ shifter in the same position as the old case and the D300 is nearly flat. I also pulled out the studs from the clocking ring and installed in the stock location.

 

[blubaru2002]

Fun build. Keep the updates coming!

 

[cccj]

Got the tcases sealed up and torqued and installed where I want them.

Cut out a piece of 1/4” for the new flat crossmember/skid. The old one will always be know as the the rock hook.

 

[lovett86]

Nice work.

 

[cccj]

Before and after on the trimmed trans mount. Up and back will help get the skid higher and tcase weight supported better.

Still working on building rigidity and mounts into the crossmember but it’s up there.

 

[cccj]

Time to pull the dana 30 and leaf springs.

Then the fenders just to make work space.

 

[cccj]

Committed to linking it by cutting off brackets.

….and pulled the replacement front axle out and got it on jackstands.

It’s an antique Currie 9” with D44 outers. Matches width (62”) and bolt pattern (5x5.5) of the rear.

 

[cccj]

I cut off some more brackets last night and added a temporary crossmember.

 

[cccj]

Today I was able to cut 2.5” off the frame rails and rotate and raise the steering box.

 

[lovett86]

Nice progress