Page 1 - Buildup
Page 2 - Wheeling
Page 3 - For Sale
Page 4 - Dash/Wiring
Page 5 - Fuel Cell
Page 6 - Buddies Rigs

Forgot to mention that I changed out the filter on my transmission at the same time we were doing my brothers, lets just say it wasn't much better than when I changed the fluid in my differentials. There was a lot of gunk in the pan and the filter was almost completely clogged. I put a new filter and gasket back in place and even with the new gasket the damn thing still leaks...I can never win. Eventually I will go to an AW4 when I have the money and time. I did pick up a transmission temperature gauge from Advanced Auto Parts were I work, part number 4357, I will be installing that soon along with a spin on remote filter for the transmission when I decide which one I want to go with. Oh and I have my eyes set on a supercharger setup for this motor that I will likely be picking up in the future after I recoup some money from books this semester.

 

 

I didn't accomplish much over Winter break from college. But my brother Dave, a friend James and I managed to piece together the steering column I wanted by combining the 1978 CJ7 column I had already and a column from a 1995 Chevy 1/2 Silverado. So now I have a fitted Chevy column with a column shifter, no tilt, a splined CJ7 steering output shaft, and CJ7 shift output. I don't have any current pictures of the column, I will get some when I go back home. Here are some current pictures of the rig, I just received my other coils, spring tenders and dual rate kit from Kustom Warehouse last week so those will be getting thrown in over Spring break, woot!

 

 

I guess I should put a little update in here. So far between work and college I haven't had anytime at all to work on this heep, I snapped some better pictures of the final product of the 4 link...and I shouldn't even say final because it isn't finished yet. And just a little update on the 4.0 head conversion, I put some block sealant in the coolant and that did the trick with the weeping water jacket, this motor setup rocks!

 

Summer '07 Project -- 4 link, hydro assist and other random poop...

 

And here's the jeep sitting on coil overs...

Went out with the Plymouth Auto Club here at PSU and did some photo shoots for the new club on campus!

 

 

Windshield hinges are on, two of the nutserts on the drivers side dropped out, so....oh well.

M.O.R.E. boomerang shackles are back on the front end, hooked the winch up (temporarily, ground is a little sketchy), zip tied up some loose wires and vent lines, checked the tcase bolts, found out my power steering return line is leaking. Also getting a weird noise from the distributor, so I'll have to figure that out later. Either way I finally got to drive it back to school, it has a LOT more power.

Just got the Kentrol windshield hinges in, so far I like them. We'll see how they hold up, and how long it takes me to get the old hinges off the windshield.

 

 

 

Well I did a lot of work with my brother Dave over spring break, worked at least 15 hours a days on Jeeps, woot.

Wiring makes me want to cry...

The snazzy new CJ-7 dash, now I need to decide which brand of gauges to run, what style, etc. Any suggestions are more than welcomed.

5/16 Tranny lines, reused one old on, brother bent up the other, I ruined several 51" lines trying to do them.

 

 

She runs and drives, head leaks fluid externally from where we epoxied the water jackets, its such a small amount I am going to run it and build a head on the side. Need to get a hold of another 4.0 HO head, and take it to a machine shop to get the jackets welded and decked. Then I guess I will try my hand at rebuilding it.

FOR ANYONE WHO LOVES WHEELING PLEASE GO HERE AND SUPPORT PARAGON ADVENTURE PARK!!!

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Back to school from winter break, had some trouble with the jeep dying on me on the road, so instead of figuring out what was actually wrong with it we tore it down and installed a 4.0 head, fuel injection, another TF999 with the CKP (crank sensor) mount, and other random doo-dee.

My brother's jeep and mine, sooooo sexay

 

 

Removed the old head off the 4.2 block, after doing so we found out the motor has been bored .030 over, so I'm estimating it's around a 4.3-4.4 inline 6 now.

After removing the 4.2 head...we found out it wasn't really a block from a 88' YJ, instead is a narrow deck CJ 4.2, this means we need to do some head work. If you look at the 4.0 block below and the 4.2 block on the drivers side you will notice the difference, the 4.0 is the wide block head.

 

 

This means we need to do a little work to the head, after discussing it for a while and looking over some write-ups online we decided to go ahead with the head work.

Basically the 87 (I believe) and newer YJ's had a wide deck block, so the 4.0 heads are a perfect match. On the narrow 4.2's though the water jackets cast into the 4.0 heads hang over the side of the block, which allows coolant to pour out, so we need to block them off. For this we took some advice from online sources and went with quicksteel epoxy.

 

 

 

Friends helping out by getting the water jackets cleaned up, we will use biodegradable packing peanuts in these in order to prevent the epoxy from blocking off the water passages. The peanuts provide a surface the hold the epoxy out, and then when coolant runs through they dissolve.

 

 

 

Packing peanuts stuck in the head, and the epoxy added...

All of the water jackets are sealed and the epoxy is curing.

 

 

4.0 head painted and ready for install

 

 

Painting the engine block with black high temp enamel.

 

 

Installed the 4.0 head, rockers, 4.0 pushrods and valve cover.

Figured out at this point that the v-belt setup isn't going to work, had to swap in the 4.0 water pump and other front drive pulleys.

 

 

Everything removed...

 

 

The 4.0 serpentine front drive installed, and 4.0 distributor installed, fuse block is in too.

Removed everything, transmission, transfercase, flexplate, torque converter, etc.

 

 

Newer tranny getting prepped to go in, flex plate with tone ring for the CKP installed...

Drivetrain all bolted up with a teraflex skidplate.

 

 

Stock skid and tera skid...

Plans for winter break are to stretch the front end and lower it slightly, move the rear spring hanger back to fix the rear shackle angle, and if I have time pop the fuel injection in and the new transmission (TF999).

The differential guards are painted and installed, axle housings drilled and tapped, don't ask about that (thanks Dave!), vent lines are in, new diff fluids, twin sticks are in, and thats about all we could manage for break. My plans now are to work on the skid plate, and get my rig fuel injected.

Diff guards installed on the axles, looking nice!

Almost didn't want to paint the bolt heads, but function before beauty.

Getting ready to install the rear cover and...Whoa, some nasty diff fluid in the rear, the front wasn't a lot better either.

Much cleaner after some brake cleaner and degreaser.

 

 

Prep and paint, I just used a brush on black metal exterior paint which we had lying around.

Twin sticks were really nice, stainless steel, mounted them according to the directions the first time, and then ended up flipping them for a better fit, and yes those are Scooby Doo sheets...

Twin sticks on the Dana 300 allow for different options, such as 2wd low range, front low range, etc.

Plans for Thanksgiving break, get the new differential guards from Dan @ Ruffstuff painted & installed (I've had them for a while now), drill and tap the axle housings for plumbing vents, run the vent lines, run a gas tank vent, and change diff fluid.

The Dana 60 and 14 bolt guards are sick, one piece 3/8" thick covers, and 3/8" rings, beefy...

Updated Pictures, took it out for some poser shots, and to test out the flex, definitely going to be doing some more work on it soon...

Jeep sitting as the house waiting to go get inspected... Definitely want to do a wheel base stretch, the rear was already stretched about 1.5" by redrilling the perches, plan in the future will probably be to lower the YJ and extend the wheelbase.

 

Completely replaced the front brakes on the Dana 60, installed new universal joints on both sides, removed the dust shields, repacked the wheel bearings, painted the high steer arms and other spots, greased steering and suspension components, and installed a fuel cell.

 

 

Jeep is looking pretty nasty with the new shoes...

 

New tires are in, Super Swamper TSL SX's, 38 x 12.50 on Military H1 rims, Stazworks double beadlocks.

Rims w/ beadlocks

 

 

Damn, sexay....the tires of course....

 

 

Built a new transmission mount using the old one and a piece of angle, goal was to lower and move the drivetrain to the drivers side, worked out alright, but by no means was it awesome.

Jeeps at the shop ready to get road ready / legal, and get some new shoes...

Pictures of the YJ on roller tires sitting in my yard...

 

 

Dana 300 with clocking ring from CJ Offroad, 3/8" thick steel. I encounted a lot of problems with the transmission pouring out ATF with this ring, I attributed to it not having a longer input shaft for the D300. The input shaft is supposed to sit up against a seal around the output shaft of the transmission, but with just a plain old 3/8" clocking ring, that moved the input shaft 3/8" away from the seal.

 

After having the troubles with the clocking ring I decided to go with a kit from Advanced Adapters, it included a 7/8" aluminum clocking ring, new input shaft, sealed shaft bearing for the D300, and two gaskets. The Advanced Adapters stuff is by no means billet aluminum, the first ring and input shaft I got looked like absolute crap, I made them take it back, and after some trouble with UPS not delivering the package I finally got my kit. Again not the best looking / quality kit, but for the money it works.

YJ waiting in the yard for the rear axle to be installed...

 

Started out with a 1988 Jeep YJ, and started going ballistic...

-Motor- 258, 4.2L, I6 (Soon to have a 4.0 head swap and fuel injection)

-Transmission- TF999, 3 speed automatic.

-Transfercase- Dana 300, clocked up flat w/ Advance Adapters 3/4" clocking ring, new sealed bearing + input shaft.

-Axles-

-Chevy Dana 60 front, 4.10's, w/ WFO high steer arms, WFO tie rod + drag link. 3/8" thick Differential cover/guard from Ruff Stuff Specialties. Brand new calipers, rotors, pads. Front brake hoses from a 98' Chevy 2500HD 4WD.

-Chevy Corporate 14 Bolt rear, 4.10's, converted from drum brakes to disc using Sky Manufacturing brake brackets, 76 Chevy K2500 front 4WD rotors, calipers, and pads. Brake hose is an 83' Dodge 1/2 ton 4WD rear hose. 14 Bolt was removed of all brackets and the spring perches were relocated.

-Rims & Tires- The rims are 2 piece military H1 rims, double beadlocked w/ beadlocks from Stazworks. The tires are 38 x 12.5 x 16.5 super swamper TSL SX's.

-Fuel Cell- The fuel cell is made by RCI, it's their 15 gallon tank, outfitted with dual holley fuel pickups, foams been removed.

-Winch- Warn 8274, about 30 years old, still chugging. Awesome winch, really fast and can pull a lot. Military has been using them for years, and Warn still makes them unchanged from what they were.

-Suspension- The springs are BDS 2" lift, double military wrap YJ springs, lifetime warranty, couldn't beat that. I flipped the center pin over and setup the suspension SOA. I was tempted to go with Jeep Wagoneer springs for the stretch, but I think I will just modify the frame for a wheel base stretch... either that or 4 link it.

The H1 Hummer rims...

Sky Manufacturing disc brake brackets, much nicer than some that are out there, no spacers, they are bent to fit.

WFO Concepts HD Dana 60 high steer arms, reamed for correct tie rod end angle, corrects the ackerman.

1.5" DOM w/ .25" wall tie rod, drag link and some beefy 1 ton Chevy tie rod ends.

 

MORE 5/8" HD shackles and spring eye kit, all brand new poly bushings, fully greasable.

 

 

Disc brake gear for the rear axle, 76' Chevy K2500 rotors, calipers, and pads.

The Jeep tear down... removing axles, springs, sway bars, trac bars, and other miscellanous junk...

Russ getting ready to have some fun with the OA torches...

 

 

The axles were borrowed from this 1985 Chevy K30, had a little too much fun stripping it down... We were attemping to pull the cab off to lighten the truck a little for the haul home, ended up flipping the whole thing over because of one body mount that just wouldn't give up

 

This is the 14 Bolt rear, took the old drums off it and setup some nice bling disc brakes. It was a pain grinding the cast spring perches and pulling off the old drums, word of advice, get yourself a BFH.

Brother Dave checking out the beasty axle shafts, BEEF.

 

 

Final product, full floater corporate 14 bolt, 4.10's, 3/4 ton disc brakes.

 

 

Shaved the spring perches down with a grinder, goal is to get the rear end down. Perch already had a hole to relocate the spring center pin, so I drilled the spring plate to correspond. Essentially what this is doing is allowing me to stretch the rear end by about 1.5 inches.

 

Links:

http://www.neow.org

http://www.domenicsautoandjeep.com/

http://www.pirate4x4.com

http://www.wfoconcepts.com/

http://www.ruffstuffspecialties.com/catalog/index.php

http://www.mountainoffroad.com/

http://www.granitestateperformance.com/

http://www.performanceoffroadcenter.com/

http://www.elias4wdcenter.com/

http://www.kilbyenterprises.com/

http://www.advanceadapters.com