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Rolling Mod
04 Wrangler Unlimited, 67 F100
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42,194 Posts
Discussion Starter · #1 · (Edited)
This not a hardcore build. I recently bought a 2004 TJU. As I’m ordering parts for the build, I thought I’d start a thread (it will be slow)

I have done tons of research before making any decision. I am a planner and I never jump in feet first. I have probably bugged the crap out of everybody I know asking questions.

This is the thread where I compared the TJU (LJ) to the JK.

https://www.pirate4x4.com/forum/general-chit-chat/2531609-bench-racing-lj-vs-3-8-jkur.html

I have 2 old world d44 ARB’s so I started this thread to discuss Gear options.
https://www.pirate4x4.com/forum/general-4x4-discussion/2644786-dana-44-ring-pinion-interchange-waggy-tj-jk.html

I also discussed all the d44 front axle options.
https://www.pirate4x4.com/forum/jeep-non-hardcore/2663512-tj-d44-questions.html

Here is the thread where I asked about Midwest cars as this Jeep was imported from Missouri.
https://www.pirate4x4.com/forum/general-chit-chat/2619250-kansas-auto-rust.html

I took delivery of the Jeep at koh. It is stock except for a 2” bds budget boost.

Here is a thread where I talk about jeeping again.
https://www.pirate4x4.com/forum/general-chit-chat/2633250-beat04lj-i-m-back-bitches.html
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #2 · (Edited)
I have taken it out to Gorman, but in stock form it’s largely helpless.
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #3 · (Edited)
So far I have purchased a used winch (thanks pbb).

I have also picked up metal cloak fenders, gas tank and oil pan skids. The fenders will be painted a body color and the grill and hood will be repainted as they have some rock chips probably from being in the Midwest. I like how clean the fenders are on SDCJ’s LJ
https://www.pirate4x4.com/forum/jeep-non-hardcore/979608-victim.html

I’m working on a new front axle from Currie with goatbuilt. A hp44. Once the axle is ready, the jeep will go to PolyPerformance, where it will receive a 2” synergy lift And the other miscellaneous parts will be bolted on.

I currently am looking at used 38” falkens or 35” general grabber. I am worried that 38” tires are too big for the stock rear end. The rear end will receive an ARB and gears to match the front. I was originally thinking of going with 4.88 gears but they may not be deep enough. I don’t have to decide the gear ratio tonight, but I have to decide soon.

I want to keep it as low as possible with as much tire as is reliable.
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #5 · (Edited)
This is my build list I’m working off of:

Jeep to do/wishlist-

Transfer lift (Here adjusting)
Seat with more lateral support. (Electric adjust)
Harnesses (haz) and harness bar.
Adaptive shifter (on order at ability center)

Replace driver side sunvisor
Rear Arb (haz).
Rear gears/bearings
Rear wheel spacers to match front width and bolt pattern.
Arb Compressor
Winch (bought)
Winch plate
Rockers
Gas tank skid (here)
Upgrade tie rod/drag link
Mount CO2 tank (haz)
Steering box skid?
Steering box brace?
Bumper front w/ shackle mounts. (For tow bar)?
TJ disconnect swaybar Or not shit discos?
Oil pan skid (here)
Front D44 tubesock style (in process)
SYE?
Fenders (at synergy)

Version2.0 (next summer?)
Rubicrawler
D60 rear
Savvy belly skids and body lift.
Soft top with working zipper.
 

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Premium Member
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3,191 Posts
You should run Currie anti-rock or an electronic disconnect sway bay. That way your care taker doesn't have to try to hook it back up.
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #7 ·
You should run Currie anti-rock or an electronic disconnect sway bay. That way your care taker doesn't have to try to hook it back up.
I would like to. The white Jeep I had an anti-rock and I didn’t feel like it was stable enough on the road. (It also had a fairly soft coil overs) I asked a few friends and they thought the Rubicon had disconnecting sway bars but it appears that that’s just a JK feature not a TJ feature. I’m still thinking what I can do. Somebody made ia dual rate sway bar with the warn hub on it but I can’t remember who.

Off-road only also made a remote disconnectable sway bar. For a time. Not sure if they still manufacture it.
 

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3,088 Posts
Just out of curiosity, could you include some tech about the hand control setup? Would be interesting to see some of the gadgetry involved for legless wheelers. Also intrigued to see the evolutions and integrations of the FrankCrane.
 

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Premium Member
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1,279 Posts
Question about the 38" Falcon tire choice...... Are those tires available to the general public? I know of a guy that has a set, and while they work awesome in the rocks, are impossible to find. He had a bunch of trouble finding a 5th tire for a spare and ended up getting a used one from Genright after a long search.
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #11 · (Edited)
Question about the 38" Falcon tire choice...... Are those tires available to the general public? I know of a guy that has a set, and while they work awesome in the rocks, are impossible to find. He had a bunch of trouble finding a 5th tire for a spare and ended up getting a used one from Genright after a long search.
I honestly don’t know. I have a sticker on the back of my wheelchair off of some from years ago that says not for highway service, but that set ended up on a UA truck and I’m not sure where they ended up.
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #12 ·
Just out of curiosity, could you include some tech about the hand control setup? Would be interesting to see some of the gadgetry involved for legless wheelers. Also intrigued to see the evolutions and integrations of the FrankCrane.
I’m still making adjustments to the FrankCrane. As soon as I get it dialed where it doesn’t take five minutes to get in and out of the jeep I will shoot a video and show everybody what it does. Right now we are very slow and it takes forever to move me in and out. I get bored and I’m actually doing it so when we streamline it a little ill post more.

I’m waiting on a shifter adapter, when it gets here I will show you the hand controls.
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #13 ·
I believe Skyjacker made the sway bar with the locking hub.

Would the JK Rubicon bar work for you? I know the frames are different widths but seeing as how you are going with a JK width axle the JK bar may fit with some mods. :confused:

Found it... https://www.4wd.com/p/2001-Jeep-Wra...MIuLqfwsXO3AIVDVcMCh3pbgEOEAQYAiABEgLtEPD_BwE
I’m not sure if the width of the JK bar will work. They are widely available though so I might check one out to see.

That is the sway bar I was thinking of. It says 4 to 6 inches of lift but I bet you could just cut down the end links and make it work with less.
 

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Has Training Wheels
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301 Posts
I would like to. The white Jeep I had an anti-rock and I didn’t feel like it was stable enough on the road. (It also had a fairly soft coil overs) I asked a few friends and they thought the Rubicon had disconnecting sway bars but it appears that that’s just a JK feature not a TJ feature. I’m still thinking what I can do. Somebody made ia dual rate sway bar with the warn hub on it but I can’t remember who.

Off-road only also made a remote disconnectable sway bar. For a time. Not sure if they still manufacture it.

https://www.quadratec.com/products/16191_5501_07.htm

I have a Sway-loc and I love it. Stiffer than stock when locked and still pulls over 1000 on the RTI ramp unlocked. Got mine used so I paid a lot less than new price.
 

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499 Posts
I currently am looking at used 38” falkens or 35” general grabber. I am worried that 38” tires are too big for the stock rear end. The rear end will receive an ARB and gears to match the front. I was originally thinking of going with 4.88 gears but they may not be deep enough. I don’t have to decide the gear ratio tonight, but I have to decide soon.
If you want to run the 38's, you are going to want to run something much deeper than 4.88's if you hope to use OD. The OD gearing on the 42RLE is stupid high, 0.69:1, and sucks even with the bone stock tires. I hated the 4.88's and 35" MTR's on my '04 LJ because it would barely pull on flat ground, especially if we were loaded up for a weekend trip.
 

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #16 ·

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Rolling Mod
04 Wrangler Unlimited, 67 F100
Joined
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42,194 Posts
Discussion Starter · #17 · (Edited)
If you want to run the 38's, you are going to want to run something much deeper than 4.88's if you hope to use OD. The OD gearing on the 42RLE is stupid high, 0.69:1, and sucks even with the bone stock tires. I hated the 4.88's and 35" MTR's on my '04 LJ because it would barely pull on flat ground, especially if we were loaded up for a weekend trip.
Blaine said things that were very similar. I think he wanted me to go with 538’s for 35 maybe 37 I don’t remember. it’s in one of the other threads. The times I have driven this jeep on the highway I haven’t had a problem with 31’s and 3.73’s, but they weigh a lot less. I do drive freaking slow anymore.


Edit: 5.38’s now.
 

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Has Training Wheels
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301 Posts
The only thing I found wrong with the Swayloc is that it tends to lock itself randomly on the trail and I broke one of the links figuring that out. Now I wrap a velcro strap around the lever to keep it unlocked. I've never had in unlock itself though.




32784875_1260705804065223_8850332033885405184_o.jpg

32725619_1260705667398570_8742911152305995776_o.jpg
 

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Premium Member
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1,864 Posts
I know comparing apples to oranges as I have the nv3550 in my hoopity but it runs right a 2800 rpm at 70 with 35's and 4.88. Decent down the freeway.

Now I wish I had lower gears offroad but hopefully that comes later with a crawl box and a flipped 300
 
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