Jeep Sahara Build

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JeepGuy21
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Jeep Sahara Build

Post by JeepGuy21 » Thu May 03, 2012 2:15 pm

My Jeep has come along way since I first got it about four years ago, looked much nicer back then:

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1999 Jeep TJ Sahara, 4.0, 6 cylinder, automatic.

Anyway, I have done alot of research and parts have been piling up in the room and garage. I finally decided to take the plunge and order my axles, suspension, new steering, skids and other misc. goodies. Big thank you to eric (Know Where 2 Jeep) for his help as well as Paul (Boodyrider) and many others who have helped me get the Jeep to where it is now.

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So that brings us to where we are currently. My jeep is severly undergeared (3.07s) and terrible to drive on the street. The suspension is wore out, ride is rough, no lockers and terrible clearance offroad due to the belly drop. It has a 4" Rough Country SL, Daystar 1" BL, 33" Baja Claws, and plenty of other stuff (skids, sound system, bedliner, flat fenders, etc.) I have been saving and building up to make a fun driver to cruise down the road, gain additional suspension travel while lowering the center of gravity, and lockers to run some more difficult trails.

Here is the build plan that I have been going over for quite some time.

HP30 with the following:
U-Bolt Yoke Upgrade
Aussie Locker
4.88 Ring & Pinion & Install Kit
Currie Mini Skids
Solid Diff Cover
Basically everything is new except the knuckles and shafts. Ball joints, seals, bearings, hub unit bearings are all new.

Ford 8.8 with the following:
KW2J Bracket Kit
ARB Air Locker
Lube Locker Seal
4.88 Ring & Pinion & Install Kit
Disc Brakes
Stock Shafts
Should be quite an upgrade from a leaking pinion seal dana 35 rear axle.

Suspension:
Old Man Emu (OME) 2"-2.5" Springs, Shocks, Bumpstops
Currie Upper and Lower Adjustable Control Arms
JKS Front and Rear Track Bars

Steering:
Currie HD Steering (Tie-Rod and Draglink)
Currie Anti-Rock Swaybar Kit
OME Steering Stabilizer

Skids:
Skid Row Steering Box Skid
Dave Halltrail Engine/Oil Skid
UnderCover Fab Works Ultra High Clearance Belly Pan
Savvy Offroad High Clearance Gas Tank Skid

As this build thread continues along, there will be additional stuff that will be changed but getting it back on the road is most important. I plan to add a nice full cage with seats and harnesses, an exhaust, and some interior work as well.

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Re: Jeep Sahara Build

Post by JeepGuy21 » Thu May 03, 2012 2:30 pm

So after dropping my axles off to Eric (Know Where 2 Jeep) as he had the best price for what I was looking to get done, I searched from local shops to online retailers and by far his was the best deal to go with.

As he is rebuilding the housings, I decided to start right away on my portion:

Me and a friend removed the rear bumper, Skid Row gas tank skid, and the Dave Halltrail rocker guards and engine skid.

Image

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Repainted skid:

Image


As I was waiting for my buddy to come back over, I decided to paint the Undercover fab works belly up pan:

Image

Next we installed the M.O.R.E. 1" MML to gain clearance for the belly up, took us a little bit but wasnt as difficult as I expected:

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We then decided to install the Advanced Adapters SYE Kit for the np231 transfer case:

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Flat Belly!

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Not Good!

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Thats as much progress we have made, still need to tear out the case to rebuild it, the ATF fluid inside was like a milshake with some water, so we will see what might need replaced.

I am sure I am forgetting some stuff and will try and update this often when we make progress.

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Re: Jeep Sahara Build

Post by Toaddragon » Thu May 03, 2012 4:55 pm

Nice work, you have come a long way with it but its good that you have wheeled it at every stage along the way. No one starts with a pro comp rig.
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Re: Jeep Sahara Build

Post by JeepGuy21 » Thu May 10, 2012 1:49 am

Toaddragon wrote:Nice work, you have come a long way with it but its good that you have wheeled it at every stage along the way. No one starts with a pro comp rig.
Thanks Mike. One day my Jeep will have a v8, dana 60's, atlas and 42s 8) But that is not the plan for this Jeep. I am making it to where I can run more difficult trails (blacks and maybe a couple reds) consistently and still drive it down the road and through any weather condition. More of an expedition rig as I would like to do some remote camping as well.

Well back with the updates, I have been somewhat busy in trying to get my half done as the HP30 is almost built. My last update was that we drained the transfer case of the fluid. That picture does not do it justice. It was alot more like a milkshake and alot of water.

We then pulled the case (what a pain the ass) and decided to do a full teardown to make sure nothing was messed up.

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Myself and my friend Greg did the install of the SYE, it wasnt actually that difficult. However since I thought we had cracked the transfer case oil screen/filter, back apart the case came again. I picked up more RTV Sealant, another quart of ATF and some misc tools. We took the case back apart again to find the oil screen in ok condition however we replaced it anyway. Checked all the gears and did another bath in brake cleaner. We then manually put the transfer case in four low since we could not put it in gear due to the Motor Mount Lift. Set everything and the case is finally done. 8) We then reinstalled into the Jeep, connected all the sensors, and I will be ordering a relocater bracket to be able to shift.

We then decided to just check the Under Cover Fab Works Belly Pan Skid and see how it would hold up. It looks awesome! 20" of ground clearance. I will NEVER lift a vehicle again if I have to run a drop pan.

Image

Thats all for now, till the HP30 is finished next week. :twisted:

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Re: Jeep Sahara Build

Post by RkyMtnH » Thu May 10, 2012 12:39 pm

JeepGuy21 wrote:I am making it to where I can run more difficult trails (blacks and maybe a couple reds) consistently and still drive it down the road and through any weather condition.
Are you going to get chromo axles or rcv's in the D30 ? What tire will you be running ? Tire size ? After a few trips trying to run Blacks or possibly attempting some REDS, driving the jeep home may be not be an option anymore. Just a thought.
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Re: Jeep Sahara Build

Post by JeepGuy21 » Thu May 10, 2012 1:05 pm

RkyMtnH wrote:Are you going to get chromo axles or rcv's in the D30 ? What tire will you be running ? Tire size ? After a few trips trying to run Blacks or possibly attempting some REDS, driving the jeep home may be not be an option anymore. Just a thought.
They are going to be stock shafts for now, but can always upgrade. Swapping from a lp30 to a hp30 will help a little. Aussie Locker in the front. Tires will be a set of 35x12.5x15 BFG KM2s when they come back in stock. I have run a couple of black level trails now with the belly drop, 3.07s and open/open. With the automatic I tend not to have a heavy foot. The Red trails that I would like to try to run would be a couple lines on Tombstone and Rock Creek. As far as driving home, I guess I better sign up with AAA. :lol:

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Re: Jeep Sahara Build

Post by RkyMtnH » Thu May 10, 2012 1:58 pm

JeepGuy21 wrote:
RkyMtnH wrote:Are you going to get chromo axles or rcv's in the D30 ? What tire will you be running ? Tire size ? After a few trips trying to run Blacks or possibly attempting some REDS, driving the jeep home may be not be an option anymore. Just a thought.
They are going to be stock shafts for now, but can always upgrade. Swapping from a lp30 to a hp30 will help a little. Aussie Locker in the front. Tires will be a set of 35x12.5x15 BFG KM2s when they come back in stock. I have run a couple of black level trails now with the belly drop, 3.07s and open/open. With the automatic I tend not to have a heavy foot. The Red trails that I would like to try to run would be a couple lines on Tombstone and Rock Creek. As far as driving home, I guess I better sign up with AAA. :lol:
The re-gear and lockers will be a major improvement on the trails. I don't know too much about AAA, but, if you know someone who has a trailer. You could pay for the gas and $50 for the inconvience. :mrgreen:
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Re: Jeep Sahara Build

Post by Cowboy » Thu May 10, 2012 6:14 pm

Anything beyond lockers and 33's is overkill for black trails.
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Re: Jeep Sahara Build

Post by wesleypipesyo » Thu May 10, 2012 11:02 pm

Cowboy wrote:Anything beyond lockers and 33's is overkill for black trails.

It helps if you have folks with winches and tow straps as well if you only go with 33's and lockers... Unless you are John in a red yj
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Re: Jeep Sahara Build

Post by Cowboy » Fri May 11, 2012 1:20 am

wesleypipesyo wrote:
Cowboy wrote:Anything beyond lockers and 33's is overkill for black trails.

It helps if you have folks with winches and tow straps as well if you only go with 33's and lockers... Unless you are John in a red yj
If your going to "handicap" it with using other people's straps and winches, 33's are overkill. But then again, I am a superior rock pilot compared to you. :flipoff:
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Re: Jeep Sahara Build

Post by relwell » Fri May 11, 2012 6:39 am

Cowboy wrote:If your going to "handicap" it with using other people's straps and winches, 33's are overkill. But then again, I am a superior rock pilot compared to you. :flipoff:
[img]
http://t0.gstatic.com/images?q=tbn:ANd9 ... Ta02Ch-SbW[/img]

Legit.

A lot of people that built their Jeep up huge wish they had a belly up and 33's and could just go run Black's all day and have fun. Going big is nice, don't get me wrong, but spend some time getting pro while you build - no point in putting it in first and napping as your 12' tall Jeep wrapped in steel just walks over every obstacle you come across.

Good luck though - good to see you cranking away on that thing.
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Re: Jeep Sahara Build

Post by relwell » Fri May 11, 2012 6:41 am

Damn! Image fail! I should probably work on being a pro at posting pics or GTFOing :lol:

Anyway, here is what I imagine a true rock pilot looks like...


Image
Image
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Re: Jeep Sahara Build

Post by ReneDave » Fri May 11, 2012 4:18 pm

JeepGuy21 wrote:They are going to be stock shafts for now, but can always upgrade. Swapping from a lp30 to a hp30 will help a little.
On 35" tires that HP30 isn't going to help you a bit when you're popping stock axle shaft U-joints like they're going out of style. Seriously, it isn't a matter of if, but when. As in, I wonder when during the day am I going to turn the wheel and give it a bit of gas and puke out a U-joint cap and likely one or more yoke ears. If you grind down the shoulders of the yokes so you can use full circle circlips on the caps they might hold up, but with the softer stock shafts and C-clips carry spares and expect to lose at least one pretty much every time out.
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Re: Jeep Sahara Build

Post by halltrail » Fri May 11, 2012 8:28 pm

ReneDave wrote:
JeepGuy21 wrote:They are going to be stock shafts for now, but can always upgrade. Swapping from a lp30 to a hp30 will help a little.
On 35" tires that HP30 isn't going to help you a bit when you're popping stock axle shaft U-joints like they're going out of style. Seriously, it isn't a matter of if, but when. As in, I wonder when during the day am I going to turn the wheel and give it a bit of gas and puke out a U-joint cap and likely one or more yoke ears. If you grind down the shoulders of the yokes so you can use full circle circlips on the caps they might hold up, but with the softer stock shafts and C-clips carry spares and expect to lose at least one pretty much every time out.
This is true...you will most likely break axles...however, I ran a lp d30 on stock shafts and an arb with 35" boggers for about two years...broke twice maybe three times....running blacks and reds. I know one of those breaks was on otters one was at the end of the day on the comp course...Gauntlet I believe.
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Re: Jeep Sahara Build

Post by relwell » Fri May 11, 2012 8:50 pm

My wheel fell off in downtown Annapolis once, so I can totally relate.
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