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Old 09-13-2009, 03:45 PM   #1
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3.5" lift, advice needed.

I have a 99 TJ sahara edition, it has a 4.0L and 3-speed automatic. and as far as i can tell a 3.73 front and rear and i believe are Dana 35 axle on the rear.
i want to do a 3.5" Rubicon express lift with Rancho RS9000XL and the wireless controller

now my questions are:

1. do i have to re-gear to run the larger tires(33x12.5)?

2. is my axle strong enough to handle the larger tires?

3. instead of doing some drilling for proper reposition of the track bars, would it be worth it to get adjustable front and rear ones?

4. a certain part draw's some concern on the front end:

i believe its known as a adjustment sleeve on the steering linkage. it just doesn't look like it is strong enough, actually its design makes no sense to me, would it be worth to replace this and add a drop pitman?

now i want to make sure i do this all right the first time, the plan is to collect all the parts i need threw the winter and do the lift in the spring. i am also going to coat the bottom in por15 anything i should avoid painting?

thanks for the help!

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Old 09-13-2009, 03:55 PM   #2
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Quote:
Originally Posted by RhcSavage21 View Post
I have a 99 TJ sahara edition, it has a 4.0L and 3-speed automatic. and as far as i can tell a 3.73 front and rear and i believe are Dana 35 axle on the rear.
i want to do a 3.5" Rubicon express lift with Rancho RS9000XL and the wireless controller

now my questions are:

1. do i have to re-gear to run the larger tires(33x12.5)? No

2. is my axle strong enough to handle the larger tires?
Yes, just don't lock it and you should be okay for a while, keep in mind a lot of dana 35's bust under heavy gas when one wheel has contact, even open, lockers just add to fun

3. instead of doing some drilling for proper reposition of the track bars, would it be worth it to get adjustable front and rear ones?if you can do both f/r adj that is the best way to go, drilling the front is not recommened.

4. a certain part draw's some concern on the front end:
Leave the steering alone unless its rusted out on you, if you feel you need a new one look at the currie unit, also don't install a drop pitman arm with a adj track bar.
Lastly, you might need a SYE kit with this kit as well as a new rear shaft


i believe its known as a adjustment sleeve on the steering linkage. it just doesn't look like it is strong enough, actually its design makes no sense to me, would it be worth to replace this and add a drop pitman?

now i want to make sure i do this all right the first time, the plan is to collect all the parts i need threw the winter and do the lift in the spring. i am also going to coat the bottom in por15 anything i should avoid painting?

thanks for the help!

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Old 09-13-2009, 04:34 PM   #3
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the reason i'm going with a 3.5" lift is i'm trying to avoid doing the SYE kit, i know a good amount but not enough to trust myself enough to do it. but if its a must i will.

also is this a sign of my rear diff leaking?
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Old 09-13-2009, 07:48 PM   #4
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Originally Posted by RhcSavage21 View Post
the reason i'm going with a 3.5" lift is i'm trying to avoid doing the SYE kit, i know a good amount but not enough to trust myself enough to do it. but if its a must i will.
theres a greater chance you will need it. I did my lift with out it hoping the Tcase drop would be good enough and it wasnt. Some other people claim to have gotten away with it but..not me.
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Old 09-13-2009, 08:48 PM   #5
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1. no but you will loose some power. im running 35" on mine with stock gears but i never drive the jeep over 50-55mph so it really doesnt bother me.

2. your axle is strong enough just dont do anything stupid offroad. by that i mean take a second and pick a good line, dont rely on the skinny pedal to get you through.

3. adj track bars are a good idea if you can afford it. my RE front bar required that the hole on the frame bracket be enlarged to i think 5/8" and that was a hard hole to drill with the axle in the way. the rear RE bar also requires that you drill some small holes to install the bracket to use a cv drive shaft. i dont know if you need a bracket to use the stock drive shaft tho.

4. steering is fine. every car or truck that doesnt use a r&p steering system has an adjuster on the drag link to center the steering wheel. your either going to need the correct drag link tool or a big pipe wrench to get that thing to move tho, it looks like its rusted pretty good.

the leak in the rear doesnt look like its comming from the pinion so i wouldnt worry about it unless it annoys you. the diff cover gasket is just rtv sealant so it is easy to reseal it.

sye kit is very easy to install so i wouldnt stress over it. start with the drop kit and if you have problems then think about the sye. it took me about 2 hours to put my sye in and it was the first time doing it. thing that took me the longest was getting the harmonic balancer off but since yours is a 99 you dont have that headache to deal with. i think the hardest thing that you will run into with the install of the lift is going to be getting those rusted bolts off, that jeep looks like its got some serious rust going on.
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Old 09-13-2009, 09:04 PM   #6
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that's Michigan for you, cause the top looks fine!



but yeah if the drop doesn't do it i will do the SYE kit, my dad has a good amount of training in vehicles so he can always help me out. but for the steering i'll clean the rust up and some painting to stop it. luckily i work in a tool warehouse so i can get pb buster by the gallon
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Old 09-13-2009, 10:23 PM   #7
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Whats up man. I ran the rubricon express 3.5 and I drilled the front track bar. Honestly It does seem ghetto and you have to be really careful and slow to make sure you get the two holes aligned, or the bolt wont go back threw. I have the t-case drop and I just added another 1/8 inch in washers to try to reduce vibration, but its still very noticable. I dont have money for an sye so asap ill have one installed. But ive driven around 400 miles on it so far and just today I was curious and shook the drive shaft and no play so I think im good for now. The instructions pretty much suck but I think I was missing some. Good luck!
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Old 09-14-2009, 07:24 PM   #8
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well, after i get the must have parts and still have some time and cash i'll do the SYE kit, now is there any cheap way to beef up my rear axle shafts?
is there another set i can install and is it hard to do? and of course is it worth it?
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Old 09-15-2009, 07:05 PM   #10
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They would, but 30 splines would be better, but the best deal would be the $600ish TJ dana 44 listed in our forsale section. Then go get a HP 30 from and XJ.. for a few hundred and be done with axle upgrades for a bit..

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