...that is taking ever so long! Ive owned the jeep since '02, been collecting parts, losing interest, selling off, losing, or trading stuff and never really got around to doing any major work to the truck until the transmission cracked last spring. And luckily I still had the majority of all the cool crap I had accumulated over the years for the build. Some stuff I had to get again, but now Im finally making some good progress on the truck and though I would share my progress with the crowd.

Its a 96 ZJ Laredo 4.0/42RE/242, or was. I put a 2" BB,up country coils, and 31s on it a week after I bought it, and just did service and some performance work on it, but otherwise left it alone, until now. The 4.0 and 242 are still in great shape, so I think I may use them in my 58 Willys Wagon project(later!!). Its musical jeep parts at my house. I guess the only other notable mod to the jeep was a taurus e-fan that had been on for several years. Also, years ago, I bought a Claytons long arm system with the subframe, crossmember, front arms, and rear 4 link setup. I installed the crossmember, subframe, and front arms, but just ran those for a while at 3.5" lift until I got around to my axle swap. So I already had long arms on the front, and the rear was ready for it.

One thing that really sucked was that i decided to just go ahead and throw in a rebuilt HP30 into the front last year for a quick fix to the shot to hell stock ZJ stuff that was in there. Everything has less than 20 miles on it before the tranny went out, and if I was swapping out the engine/tranny, I was going bigger on the axles too. So Ive got a spare HP30 that i think will end up in my 88 2wd MJ.

So here's an old pic of the ZJ(in its larval stage).

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/ZJBV1.jpg

Then the truck shit the bed, and got rolled around back. Crammed it in with the Willys.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/zjside.jpg

http://i869.photobucket.com/albums/ab259/mrfreeze555/0623101617c.jpg

Started stripping the Jeep

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/readytopull.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/upandout.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/powertrainpulled.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/emptyenginebay.jpg


After the powertrain was pulled, the tranny was sold for scrap and the 4.0 and 242 went to my storage room to await their next ride. Next, came the nice new HP30 I had up front.

Impressive suspension travel...

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/maximumdroopbefore.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/axles.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/stripped.jpg

That HP30 should be perfect for my MJ. I also happen to have an 8.8 laying around waiting for it too, so theyll go in with leftover parts from my ZJ, its an ongoing project as well. I need a garage!!!

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0995.jpg

Problem: Sloped ground. Makes setting up accurately a bitch.
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/hillangle.jpg

Rear axle yanked.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/d352.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/rearaxlepulled.jpg

Once it was stripped this far, it was time for the interior too. I am upgrading to a Limited auto climiate control system and 5.9 leather heated seats, and 5.9 interior(I think), among major stereo upgrades. I also plan on upgrading all the wiring and replacing the heater core and evaporator for longevity. While removing all this(and my ABS system) I found a bunch of corroded wired and melted connections throughout my ABS system, but everything else was in perfect shape. I didnt need ABS anyway :D

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/zjnodash.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/baredash.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/absplug.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/abspumppulled.jpg

Alright, got everything removed, time to start putting things back together, at least to a degree where I can move the thing around again first.

Ive been through a few different options for the front end, and here is what I ended up with.

79 F250 HP Dana 44 narrowed. Im using a waggy long side shaft 32.2", but a dodge short side shaft, 16.5", .6" longer than waggy IIRC, so just slightly wider in the housing than waggy width. But I am using F250 8 lug outers, so I should end up at 64" WMS. I rented a chop saw to cut the axle tubes, but it was shit, so I just did it by hand with an angle grinder and some hose clamps.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0012.jpg

Half ton and 3/4 ton HP 44 housings

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/HP44centers.jpg

Cut the knuckles

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0005.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0996.jpg

3/4 ton Ford knuckles and big dual piston brakes. Ive got everything from the spindle out new in the basement along with new balljoints and service parts, we will get to that soon.

This diagram really helped me out when I was figuring out my axle width. I added a few, and mad a few corrections to the original that I found.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/axlehousing.jpg

I began the reinstallation process by installing a new drop pitman arm for a Waggy to match the throw of the high steer arms.

Drop Waggy compared to stock ZJ

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/pitmanarms.jpg

With Sky MFG arm

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/steeringarms.jpg

I didnt realize at the time when I ordered the pass side high steer arm, that the driver was a shorter arm for crossover only, and I am using inverted T. Ill keep the set and use it on one of my other axles, but Ive got a set of Parts Mike arms on the way now and should be here this week.

My brackets are a combination of Ballistic and RE. None of it fit quite right and was a PITA on this axle, but we got it to work. The coil buckets are from a ZJ rear axle and sit the coil directly on top of the housing. The coils are IRO.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0476.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0477.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0478.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0479.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0480.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0481.jpg

Time to get it mocked up for a trackbar. I did my best to get everything close and will have to hope its close enough once its on level ground, it should be fine. If not, Ill make a new bar, no big deal. I used 1.5" 1/4" wall with 3/4, 3/4 rod ends. The frame end has hi-misalignment bushings and a 5/8" bolt to fit the wider trackbar mount I already had(Kevins old style). The axle was pushed forward a bit by the bracket placement, so the arms length for 3" lift was pretty close, they might need to be extended just a little. The uppers need to be shortened a bit to rotate the axle up a bit too, but otherwise, everything is pretty damn close for a first time mock up fit.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0509.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0510.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0514.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0513.jpg

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0512.jpg

Ill get my trackbar welded up in a few days and will be done with the front suspension and ready to move on to the knuckles and steering. I need to get the front suspension done and on its own weight so I can start with the engine installation.

Once I can get the front on its own feet, I can start the engine install. Its a rebuilt 5.2L with a few goodies added in.

Mopar cast Jeep valve covers. The stock exhaust manifolds will be replaced with Edelbrock TES header system before installation.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/valvecoversinstalled.jpg

Crane roller rocker conversion

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/cranerollerrockers.jpg

March underdrive, and PSC power steering pullies

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0946.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0947.jpg


Ive got new everything for the engine in the basement, hoses, filters, seals, blah. blah, its ready to go in. Once it goes in, the tranny is ready to go in. Once thats in, ive got a fancy new Novak Conversions dana 300 Flip adapter ring for installing a dana 300 in a driver drop orientation. I have the 300, but havent really started in on it just yet. Once the tcase is in and I have a output shaft to point at, the Spider 9 goes in the rear

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0980.jpg

Im hoping to have the engine/tranny installed in the next few weeks and the rear axle housing welded up. Then I can move it again!! That will be nice and will mean I can move if I want(to a house with a GARAGE!!)

So thats where Im at right now, with hopefully lots more progress to come in the following weeks.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0516.jpg

nice start. i reused my old coil pads too. one less thing to have to make.

oh and that rear axle is nice:smokin:

whats the plan for gears and lockers? tire size?

and some advice, put a cage in through the dash while you got it tore down as much as you do. i hope you plan on a cage in there somewhere.

nice start. i reused my old coil pads too. one less thing to have to make.

oh and that rear axle is nice:smokin:

whats the plan for gears and lockers? tire size?

and some advice, put a cage in through the dash while you got it tore down as much as you do. i hope you plan on a cage in there somewhere.

Yeah, a cage is planned and should happen once the vehicle is moveable again.

I had a nice new set of 37" H1 12 bolts but ended up selling them in a time of need, so I need new meats. Probably 35-37 with about a 4" BS.

Gears are 4.56, rear axle is a 35 spline detroit, front is still up in the air for diff. Ive got a 44 track-lok that I might use, or Ive got an open carrier. The front diff isnt a huge priority just yet, but the D44 master diff install kit is the only thing I have left to purchase for the entire front axle.

I HAD to reuse my coil pads on this one. I could not find a aftermarket set I liked. I had some ballistic ones, but could not use my bumpstop extensions with their uneven coil retainer that still allows the coil to move. I also wanted the coil directly on top of the axle, and these accomplished that as well. I will hopefully br using this same type coil bucket front and rear on my rig if I can find another set.

i ended up using the ballistic ones on the rear axle. i have yet to get the bumpstops worked out back there, but havent had any issues with the coils moving around. if so it wouldnt be hard to weld a block or something inside of the coil to keep it from sliding around.

i ended up using the ballistic ones on the rear axle. i have yet to get the bumpstops worked out back there, but havent had any issues with the coils moving around. if so it wouldnt be hard to weld a block or something inside of the coil to keep it from sliding around.

I have a set of Ballistic pads and they will work for my rear application since the bumpstop is outside of the coil spring, so I can just use a leaf perch or something for that on the rear, but on the front, I am using extension pucks bolted to the front coil buckets, so I needed that level surface for the puck but without interfering with the coil. The one thing Im not too keen on with my current setup is the front of the coil buckets are kinda vulnerable to a front on hit, everything else is nicely tucked. So they may get some skids made when I put the sway bar mounts on. I am really pleased with how these coil buckets worked out on the front axle, everything clears nicely, and there is plenty of room for my track bar and steering. Im hoping to get the front steering in soon, my new arms should be here this week!

I am pretty sure I will end up having to make a new track bar. Im on sloped ground and find it completely impossible to get everything level and lined up properly, plus the engine weight isnt in. But its all good since I have extra tube and inserts, so Ill just make a new one once the weight is on it. This one will be close enough until then.

Looks like a nice start, but take those damn cinder blocks out of there before you get killed. Why only 4.56's, why not go deeper? Any plans for rocker cut outs, unibody plating or bumpers?

Looks like a nice start, but take those damn cinder blocks out of there before you get killed. Why only 4.56's, why not go deeper? Any plans for rocker cut outs, unibody plating or bumpers?

The cinder blocks are only under the truck while it was a bare unibody, and I wont get underneath it, I just dont have tall enough jack stands. Im getting the front suspension and axle worked out now and that will support the weight properly so I can move forward with everything else. But yeah, I dont work underneath it like that. I can pretty easily shake the entire vehicle by hand, but there really isnt much weight there in its current state.

4.56s is what I had available, and seemed to be an acceptable ratio for a good V8, auto, and good highway manners. Im more concerned with building a reliable and stout dual purpose rig that will see more road than trail unfortunately. But Ive always felt if its going to be built, its going to be built right, which is why its taken so long to get the build started since it took a complete teardown. I want the truck to be overbuilt for the offroad use I plan to give it. Reliability is key, but building this truck in a full overhaul fashion is my alternative to buying a new DD vehicle. This vehicle has the possibility of 3000mi road trips in its future.

Unibody plating would be nice, but Im no good at welding, and cant move the truck. I might consider it if I could find a premade set, but I havent had any luck in that dept. I dont have time to make my own, and dont want to pay someone else to make them. For bumpers, Ive always like the trailready rear, but its $$ and has limited options. I like the RLC bumpers here on pirate though and will probably go that route front and rear for their good looks and reasonable cost. Im not going to cut the rockers out, but may reinfoce my rock rails some more. Theyre currently tied into the suspension subframe and the unibody and are welded on in several places. I would like to try to tie in the future cage to part of the rails.

Im going to use Bushwacker cut out flares to widen the stance a bit, and to get a little better clearance. Im also trying to keep it at a manageable height without massive cutting, but I think 35s will be a nice fit for this setup for most of its use, but it should easily clear 37s, and was actually the original plan when I was going to make this a trail only rig, but now its going to see lots of road use, and my Comanche will become the trail only rig, so that one I can go nuts on if I want to, but I need a reliable driver first before I tear into that project.

It that a 9" with 14 bolt hubs and disk brake conversion?

It that a 9" with 14 bolt hubs and disk brake conversion?

Good eye. Spidertrax Spider 9(first EVER! made with 3/8" wall tubes, hehe) with chromoly spindles from Rockcrusher. I bought the spindles back before they went under and got bought out and machined them to fit the tubes. Now Ballistic makes the same type spindles that dont need to be turned down and I think Solid does too. Ive had this axle since 06, so the market has changed a bit, but at the time, this was the first axle of its kind and its too bad I didnt get it installed then! Now Ballistic makes a lot of these same type parts but in super sexy aftermarket fashion. The hubs are 14b SRW hubs from the junkyard. If I had the extra $$, I would jump all over Ballistic's billet hub setup, but I cant afford it. The WMS comes to 64" on the dot. Brakes are 77 K20 fronts, stadard 14b disc brake swap stuff.


Theyre press fit about 4" into the tubes then welded.
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/14bspindle.jpg

wow thats pretty cool, so what shafts will you be using? I am assuming that your 9" shafts wouldn't work and the 14 bolt shaft even though they are 31 spline like some of the ford axles, arent they a larger diameter? Thanks for any info, i have had a 9' sitting around for awhile now but didn't want to buy an expensive disk conversion kit that some companies put together. If I know what you are doing maybe i could get my project going again, and get a full float 9"

wow thats pretty cool, so what shafts will you be using? I am assuming that your 9" shafts wouldn't work and the 14 bolt shaft even though they are 31 spline like some of the ford axles, arent they a larger diameter? Thanks for any info, i have had a 9' sitting around for awhile now but didn't want to buy an expensive disk conversion kit that some companies put together. If I know what you are doing maybe i could get my project going again, and get a full float 9"

The 9" is a 31spl that is 1.3x"(in a hurry, dont rememeber the exact spec in my head ATM) in dia. The 14b is 30 spl, but 1.5" dia, well, at the splines. The rest of the shaft is smaller, just a hair larger than the 9" splines. Soooo, I got a set of Yukon alloy 14b shafts that were too long on MAJOR sale a while back. I am going to have them cut down and splined to 31 spline and use them for winter driving. They should only need to be turned to make sure its true, but the dia is spot on, they should be able to just be splined as is.

The GM Dana 70 used the same hubs as the 14b C&C, and that is actually what these hubs are, are GM dana 70 hubs. They came off an old GM RV I ran across. And the Dana 70 is, as we know, 35 splines. The axle flange bolt pattern on the 14b/GM D70 is different than the dodge/ford/IH flange bolt circle, so it made sourcing shafts difficult. But luckily, since that GM dana 70 existed, I have found cut to fit(~6" of spline length) 35 spline shafts from Yukon with the correct, GM bolt circle on the outside end. If I had run across a SRW Dana 70 ford or dodge hub, I would have jumped on it, for the more common bolt circle, but they are very rare and I have already replaced the seals, bearings, and races in these. Theyll do just fine, and they were only $10/pr at the junkyard.

Im using a 35 spline detroit in the rear with a nodular third member, but with my spare parts Im putting together a stock case, 31 spl open diff with the same gear ratio. Ive already got all the parts for it but the carrier. The only 35 spline open diff for the 9" is an ARB, which I dont like and dont want. I have yet to purchase my nodular third member and detroit for the rear, but that wont come due until I actually have the rest of the jeep together almost.

Hey Man,

Wouldn't happen to have a Dana44HD tru-lock for sale would you? My ZJ needs a donor.

G9

Hey Man,

Wouldn't happen to have a Dana44HD tru-lock for sale would you? My ZJ needs a donor.

G9

Im not sure what a tru lock is, but I do have a D44 trac-lok that Im considering getting rid of.

OOooo, Im getting impatient waiting on parts and weather! And money; stupid paychecks. My knuckles and caliper brackets are at the powdercoaters now and should be ready later this week. My Yukon Extra HD nodular 3rd member and daytona pinion support came in a few days ago and holy shit! are they beef!

I decided to change my coil mounts up on the rear end and instead of using the ballistic coil mounts I have, I ordered a set of TnT Customs front coil buckets with the single shear shock stud that offsets the coil forward of the axle. Im going to cut the stud off and use them on the rear. They should be here later this week. I should be getting my Ballistic pinion guard soon too.

Ive got just enough room(I think) to run a TJ sway bar on the axle with custom links. Im mounting it to the axle with a set of 2" leaf spring perches, which just barely fit narrow enough with the truss.

Ive got the axle set up in my living room right now while I wait on the last bits to come in so I can really look it over an make sure its how I want it before I send it off to the welder later this week. Im hoping to be able to pick it up and install it by weekend after next and finally have this truck stand on its own. Weather permitting of course. Right now, its snowing and in the single digits, and tomorrow's high is -1, so its gonna have to warm up a smidge in the mean time, but it will. It always does :D

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/rearaxle.jpg

Oh, I almost forgot. The track bar is welded up and I got it installed last week and removed the ratchet strap! The front end is supporting itself!

I picked up some parts from the powdercoater yesterday. My knuckles and caliper brackets got PC'd and I installed all new hardware and balljoints. I had a balljoint go wonky on me and get chewed up, so I will have to replace it tomorrow, and Ill throw a coat of paint over the whole assembly to cover the bare metal arms and around the edges of the PC. I had to drill out the arms a bit to fit over the 5/8" studs, but finally got them on.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0529.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0532.jpg

Question: Are the GM front spindle locknuts the same thread size/pitch as my Ford 3/4 ton front spindles? My rear axle is running 14 bolt hubs that use the GM 6 prong locknuts, but the Fords use a 4 prong locknut. I have both 4 and 6 prong sockets, but I want the vehicle to match front to back and only require one special hub tool.

I was hoping to have my rear axle back from the welder before the weekend, but no such luck. Its ok though, I had to work yesterday and didnt have much time today to do a lot. But I did get my knuckles installed to start mocking up steering. I immediately noticed that my original idea to do a high steer Inv-T is not going to work, the tie rod hits my track bar mount. So after some thought, and a few broomsticks, I think I have found the best setup. OTK tie rod, and crossover draglink. Good thing I didnt build my steering links yet :D I ordered the tapered reamer this weekend along with my 35 spl 9" detroit, which should be here later this week. Yay! for new parts!!

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0534.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0535.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0536.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0537.jpg

I picked up my tie rod ends today. It took me a little while to find everything I needed, but I think I got all of the right part numbers. 3 out of the 4 TREs I got are Moogs with lifetime warranty. For the drag link, I got ES2027L and ES2026R, and for the tie rod, I got a ES2234R. None of the parts stores locally and most online did not have the elusive ES2234L, and have seen where people recommend the ES2010L, but DAMN is it expensive(~$60-75 is what I found, compared to about $30/ea for the Moog TREs). I found the ES2234L for $15/ea here (http://eastcoastgearsupply.com/i-4277195-es2234l-tie-rod-end.html). Im not sure the brand, but I ordered 2 so I have a spare. Ive already got my Spidertrax hex inserts, but need to pick up some DOM this week to make the links. My tapered reamer should be here mid week so I can ream the knuckles for OTK tie rod. It looks like the high steer arms may be in the way of the tie rod end until it is installed, so I may end up having to pull them loose to put the TRE. I hope not. Im hoping the TREs slip into the knuckle better once it has been reamed out since its a close fit now. Hopefully, if all goes well, I should have this steering stuff ironed out next weekend I hope! And hopefully the rear axle too! Depends on my work schedule really.

Rig looks nice man but if your doing all this fab from stratch why keep the rubber bushings? Radius arms tend to make short lift of em....

Keep up the good work. Freerider, Oneton, me and a few otherd are all within 100 miles...we'll have to do a meet and great. Or wheel.

Rig looks nice man but if your doing all this fab from stratch why keep the rubber bushings? Radius arms tend to make short lift of em....

Keep up the good work. Freerider, Oneton, me and a few otherd are all within 100 miles...we'll have to do a meet and great. Or wheel.

i'll bring my big wheel tricycle =(

Rig looks nice man but if your doing all this fab from stratch why keep the rubber bushings? Radius arms tend to make short lift of em....

Keep up the good work. Freerider, Oneton, me and a few otherd are all within 100 miles...we'll have to do a meet and great. Or wheel.


A good point, and one that has been brought up before already. I intially was building this axle to use the superflex joints for the UCAs, but this truck will for sure see extended road trips, so I thought the rubber would help keep my teeth from rattling the whole trip :D This truck has to have good road manners. At least, thats what the welder told me when he took it upon himself to weld those on instead of the joints and I didnt feel like fighting about it since I was already dealing with them welding on the wrong coil buckets(and not even once looking at the list of things I wanted done that I left with the axle). So, um, yeah, Ive got rubber bushings.

On a side note, Ive still got the joints, and another HP44, and OH!, another jeep. so theyll get used :D.

So I dropped my rear axle off at a local 4x4 shop near my work a while back. They were less than a mile away and I went with them because they were so close since I always have trouble getting anything done during business hours since I work so much, so this place was convenient. They did my front axle, and I wasnt completely pleased with how things went, but they did good enough work and I figured the rear axle work be a fairly no brainer, so I left it with them. Nearly two weeks later, they had not returned any of my phone calls asking if/when it would be done. I managed to make it back into town right at 430pm on friday and stopped by to see how it was going before they closed. They had not even touched the axle yet and it was tucked away in a back corner, so I said "gimme!" and took it with me. Then I did what I should have done in the first place, hit up the local 4x4 forums to see if someone else could do it. I found a guy 10 min away who would do it for a case of beer over the weekend. DONE! So I spent the day over there today getting it all burned in. He did great work. It ended up running a bit longer and more involved than either of us anticipated, so I kicked him some $$ for time and materials, but its not nearly what the shop would have charged me, I guarantee it. I am really pleased with how it turned out, and Im sure it will be better than if the shop had done it, because I was able to be there and make sure everything went exactly where it was supposed to, and also to be able to help out.

The housing has definitely gained some weight, but still only tips the scale under 115lbs, with gobs of ground clearance. I need to do a once over with the flap wheel and smooth some edges and knock off the spatter, but otherwise, this axle is nearly ready to go in. Hopefully next weekend will have this truck on all 4s again. And my Detroit and tapered reamer get here monday!! Im excited!

My TREs came in and look like they should do the trick. I had JUST enough scrap DOM left over from my track bar to make my drag link(like within 1/8"), so I need to pick some more up for my tie rod, but in the meantime, I am using a waggy tie rod since it is about the right length. Ive got everything I need for my steering links except the one piece of DOM, so as soon as I get it, Ill have my steering all done. I am going to try and get that accomplished this week so I can complete the steering and suspension next weekend.

Im so excited! Its finally coming together. Welding the rear axle was the last major infrastructure hurdle, now I can really get moving!

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0539.jpg
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Yesterday I was lucky enough to work for nearly 15hrs, so they scheduled me for a half day today, and the half fell through, so I had the day off! And it is gorgeous outside, so Ive been working on the Jeep today.

I got the rotors and wheels on and got the front end standing on its own, and then used the newfound stability to resupport the vehicle with jack stands and make it more stable and safe.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0548.jpg

I just realized that I received the wrong install kit for my R&P(wrong carrier bearings), so that was a bummer. Luckily, the vendor is having their supplier ship me a set of carrier bearings that will work instead of having to return the whole kit. That should allow me to still be able to set up the rear third this weekend. I am about to give the rear axle a quick once over with the grinder to clean up a few spots before I paint it.

Ive still got a few hours of daylight left, but Im tired now and am waiting on a pizza and drinking beer. Im rapidly losing motivation to get back up, and a nap is starting to sound REALLY good. Although watching my neighbors playing dodgeball on the roof of their 2 story house is quite entertaining :D

Although watching my neighbors playing dodgeball on the roof of their 2 story house is quite entertaining :D

:laughing: And you've provided no pictures or video of this because....?

Finally got the damn axle in! I still need to adjust the arms some more but its close. I do wish that I had gone with offset coil buckets though, and not centered ones, would have fit perfect pushed back a few extra inches. I need rotate the axle a good bit still, but will get to that later. The truck is finally back on all fours and can be moved again, well at least once I refill one of the tires that went flat sitting. The coils are sitting all wonky since the axle is rotated, and the coil retainers arent tightened, so they can move for the moment.

I also wish I had stuck with full width instead of narrower. My axles are 64" wide, and I think they need to be wider. I will likely be running stock style wheels so they will have more BS, so I think spacers are gonna be needed. Im not that worried about it right now though, I dont have wheels or tires yet, and Im just happy that the thing is back on all fours. Im going to rest for the rest of the day, enjoy a few cold ones and consider it a day well spent.

These axle have some really nice ground clearance, even sitting on 31s. Im really happy with the way its turning out. Ill be ordering my correct rear springs next week after I get paid, along with the last of the fancy bits I need to install before the engine goes in like my headers. Hopefully 2 more weeks will see the engine ready to go in with some extra BLING!

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0556.jpg
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I finally put some time into the Tcase. I tore it down and everything looks good. The only things showing any signs of wear were the gears on the output shafts, otherwise everything looked great inside. I got it fully torn down, and this week my front and rear output shaft kits came from JB Conversions. Wow these things are nice! 32 spline front and rear, 1350 CV flange for the rear, 1310 CV yoke for the front. I wanted to get 4:1 now too, but theyre out of stock until May, so I will address the 4:1 later down the road. Ive also got a Novak flip adapter waiting to go on as well. Im dropping off the case at the powdercoaters hopefully this weekend, or monday if theyre not open tmrw. I also need to drop the front bearing retainer off for machining for the new output shaft, and to cut the shift towers off since Im running it flipped with cable shifters. Im still waiting on the rest of my rebuild parts to come in: roller bearings, thrust washers, springs, shifter seals, etc. Should be here by the time the case is ready. If Im lucky Ill have the case powdercoated and the front retainer machined by next weekend so I can put it all back together, but I think it unlikely from past experience :( The powdercoaters are pretty slow.

My house reeks of gear oil...

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/0401111820b.jpg
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Woohoooooo!!! I finally got the engine in! It wasnt too bad of a process. Still have LOTS left to do to get it running, but I feel like Ive cleared a major hurdle now! Now for all the little details that will kill me...

I sold my Comanche thursday, so I finally had the room I needed :D


http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/engine1.jpg
http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/engine2.jpg
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http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/engineinstalled1.jpg

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0561.jpg

Hopefully this is some illusion....

What the hell is goin on with your rear coils? One looks bent forward and the other back?

And thats looks like an awefull lot of threaded rod showing on that lower link....

In that pic, the coil was sitting all wonky, it slipped off the mount(flat mount) since the retainer wasnt tightened down. The one on the right is closer to normal. Those coils were only temporary until my new ones came in. The new coils are thicker and fit the retainer a bit better and sit in a much nicer fashion now. They seem to have a flatter profile on the end when compressed. And the lower links have plenty of thread left, it looks like more in the pic. I had originally planned on using offset coil buckets to stretch the rear but had issues with the company I ordered them from and ended up using what I had, but the links were already sort of adjusted out. Currently the rear coils are much happier but still have a slight bow to the back since the rear axle is back a bit to far still. But everything is close, and I will be taking the vehicle in soon for a 4 wheel alignment since the rear end is a little off despite my measurements. But I am still playing with the exact placement of the rear axle. I want it farther back, and there is some room, but the coil orientation wont quite allow it. Its making me even more pissed that I could not get the coil buckets I wanted(and got screwed out of time, and $$ to boot!). And the axle still needs to be rotated up significantly for proper pinion angle, its almost flat right now. The LCA mounts should end up even with the tube.

http://i869.photobucket.com/albums/ab259/mrfreeze555/ZJ%20Overhaul/IMAG0599.jpg
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