HuLuD's Build Thread-2000 Wrangler Sport

[HuLuD44]

Here we go, Its been a long time coming for this thread. Follow and enjoy!

2000 Jeep Wrangler Sport - 4.0 6 cyl - Purchased April 05' - Bone stock - 45,000 milies - 1 owner.

I picked up my Jeep after I get out of the military. It's the first and only Jeep Ive owned. I fell in love with wranglers when I would come home on leave. My dad has an 03' X which I would drive since I had no car in NY. So when it came time to get my own, there wasn't a second thought. All of the pics I had of it were lost in a computer crash so here is a pic of another bone stock silver TJ just for reference.



It didnt take long to start the modifications. Since this thread hasnt been started from the beginning, im trying to back track and document everything thats been done to the best of my memory.(and thats not saying much) Heres a down and dirty list of what I can remember doing in what order. Ill try to throw some write ups in here too.

31x11.50x15 Mickey Thompson Baja's
Crager Soft 8 rims 15x8x4.0
3" BDS kit
Hood mounted High lift Jack
Hidden hitch 3" receiver
Side view mirror relocation brackets
Half soft doors
dodge durango steering box swap
Full interior Hurculiner
Pioneer MP3 deck w/ Ipod wire
Smittybilt XRC Front stinger
Rugged Ridge rear corner guards
Currie HD 1 ton steering
Currie HD adj track bar
Ironman 4x4 fab Adj UCA and LCA
Custom Rock sliders
Bed lined windshield
Upgraded to 33x12.50x15 Mickey T Baja Claws
Us Wheel Black Steel rims 15x8x3.75
Ironman 4x4 fab HD Adj rear track bar

Im sure theres others that Ive forgotten...


Like every Jeep that actually gets USED, there were ure hickups along the way. So heres a recap of to BAD days...hahaha

Bad computer - replaced coil pack, plugs, alternator, and computer
Complete submersion in saltwater tide pool- 12/31/08 - rebuilt tranny, starter, turn signal switch, fuse box,
Front end collision- (not my fault) - new bumper, radiator, fenders, and hood.
Other wheeling wounds - Crushed rear DS quarter, smashed lights, crushed rear PS shock, torn break line, bent control arms, blown u joints, drive shafts, and U joints - the usual...
DEATH WOBBLE SURVIVOR!

Again, Im sure theres more Ive forgotten...

For almost a year I had an incurable DEATH WOBBLE. I tried a lot of little things to fix it and finally said F*ck it, got Currie HD steering, Currie HD adj track bar, and Iron man 4x4 UCA and LCA and did this write up...

Control arm, track bar, and HD steering install. - JeepForum.com


Next big write up was for the Modern classice enterprises CJ style Flat fenders.

http://www.outlawedoffroad.com/diy-c...r-install.html

Next big undertaking was to build a set of rock sliders. Heres is the write up I used from JF. Worked great. Again the pics of the build were lost.

Custom Rock Sliders for Dummies - JeepForum.com

And here is another more recent one for the new Rampage Bowless fast back top

http://www.outlawedoffroad.com/gener...tback-top.html

I do wish I had done a better job of documenting everything Ive done with the Jeep but I never had an intention to run away with the hobby. So I guess that about takes it up to present day. Time to merge this with the other thread and create the final Build thread.

Here s one last pic as I sit right now. June 14 2012

[HuLuD44]

got some work done today. Installed the HD rear adj track bar from Iron man 4x4 fab. Beautiful part. Everything I get from them has been top notch. Track bar went in with no troubles. Luckily, I replaced the hardware not to long ago to some nice grade 8 hardware to get rid of the shitty torx bolt that was on the axle side of the stock track bar.

Here you can see the size difference from the stock part.







Also finally got around to taking care of the leaking break cylinder thats been gushing fluid for a few weeks. I figured while I was in there might as well do some fresh shoes and springs. berm gave me a hand with the break assembly because drums are a PIA. Thanks berm....

[HuLuD44]

Here is a re post from the other thread for the axle build. Gonna go threw and copy everything into the build thread. So sorry if some of you have seen these posts. No real better way to do it.

First Step in Double Axle Overhaul.

1. Full rebuild of HP dana 30-
- Full sand blast, prime, paint
- New seals, Ball joints, upper control arm bushings
- Re gear 4:10
- Chromoly shafts and U-joints, Prob stay 27 spline to match my Aussie locker
- New HD diff cover
- Reuse current hubs and calipers (Mine are in great shape)
- Reattach to current front end set up, Iron man CA, Currie HD steering/TB
2. Ordering Complete overhauled Ford 8.8 Axle with TJ brackets.
- Axle upgraded with Rok crawler 4-link system and trussed.
- Adv Adapters Shorty SYE with Custom Double cardan shaft
- Iron man Adj Lower CA's
3. Install 1" DS body lift (sitting in my garage)- after that Will be able to clear 36"s

Im not really in any HUGE rush but I plan on having every thing done by late winter. Gonna be a lot of work but its definitely necessary if I plan on sticking with this hobby.
Plan on making this a real deal build thread ill also link to my JF page. So keep an eye out....

[HuLuD44]

Did a little more work cleaning up the axle. Removed the upper CA bushings, tried to get the sway bar pins out but failed, decreased and wire wheeled the hell out of it. Haven't touched the knuckles yet. And the ball joints will be removed right before I put the new ones in when I rent the press. Next step is to finish cleaning the knuckles then its off to prime and paint. Started looking into the parts list. Filled my shopping car on 4WD.com. Upper CA bushings, ball joints, inner axle seals, and pinion seal to start with. About $135. Once I get all that stuff installed then I ll start looking into the gears and shafts.

Also did a little fabricating. I've had the problem in the past of the bolt hole on the track bar mount wallowing out. So i made a template, cut and drilled a stiffener plate to weld on the the mount. Used some 3/16 steel I had laying around from my rock slider build. Ill be making a thread about this and am thinking about taking orders if anyone else is interested. keep an eye out for that.

Here are some pics from tonight.

[HuLuD44]

Took it another step today. Paint and Primer. Gave it a good wipe down. I kept it greased up with WD40 for the last week after it was striped. Kept the oxidation off well. I use 3 different products today. Some how forgot to take a picture of teh etching primer. Its a cool green/gray. Would look good as a full paint job.

Rust-oleum self etching primer -
Rust-oleum auto primer
Rust-oleum flat enamel

I love these products. I use them for everything. There durable as hell and easy to touch up. 15 min between coats, 30 min between different products.

[HuLuD44]

New update: Ordered a whole bunch of new goodies for the HP dana 30 build.

-HP Dana 30Yukon 4:11 Reverse Ring and pinion
-ECGS Reverse Master Overhaul kit :
-Carrier bearings
-Pinion Bearings
-Pinion Nut
-Pinion Seal
-Crush Sleeve or preload shims
-Pinion Shims
-Gasket or RTV
-Loctite

[HuLuD44]

Gears, carrier, and master install kit arrived today. Pretty excited. Im glad i ordered the master some leeway when I mess up a few times... hahah
still waiting on the ball joints and UCA bushings. Was hoping to get that out of the way before doing the gears. And still have to get a hold of a friend who said he has the necessary tools to do the gears. Presses, torque wrenches, etc.... more updates to come
[IMG] Uploaded with ImageShack.us[/IMG]

[HuLuD44]

Made some good progress last week on the HP D30 build. Berm ordered a ball joint press and it worked like a charm. Amazing what the right tool for the right job does.

So we got out the old B joints , installed the new ones from crown. Did the UCA bushings and finally got around to sand blasting the knuckles. Came out alright. Wasnt really a great set up to do sand blasting. Didnt have the right cabinet or protection. but it got the job done. After, hit them with some etching primer and still debating if i should hit them with a color of just leave em black.

So all thats really left is for the gears to go in. Opened up the Master install kit and figured out what every thing is for. Now just have to find the right tools. Next week I plan on ordering the rear UCA, LCA, and adj TB from Iron man 4x4. Here are some pics...

[HuLuD44]

Got the knuckles painted and installed the other day. Its soooo nice to be working on something so clean. No grease or grime. Everything goes together so nice. Ordering the 12 ton press tomorrow, monday. So Im prob gonna start the gear install next weekend.

[HuLuD44]

Ordered the 12 ton shop press from harbor freight today. plus the 10 piece bearing and seal driver. Hopefully it comes by the weekend so i can get this thing started!

12 Ton Shop Press

10 Piece Bearing Race and Seal Driver Set