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Old 02-23-2013, 07:05 AM   #1
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Ok so it's not quite March but I couldn't wait:P'' I will be working on it mostly in March cause the parts won't arrive till Feb 25-27. I'm going to update this thread as I go along. Maybe it will help someone else. More likely someone will help me.

A little background. I purchased my Tj a little over a year ago. Came with:
4" OME Sl with adj tracbars and homemade discos.
D30 and d35 geared 4.56 with trutrac in rear
And a few other mods not related to this project. It's what is missing that's important.

I drove and wheeled last summer thinking the vibes and lack of handling were just the nature of a lifted Jeep. Ignorance is bliss. Then I started reading threads on this forum. Soon I joined and started ask questions and searching. Armed with my new knowledge I crawled under my jeep and this is what I found.

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As you can see no jounce stop or cup on the front.

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No extensions in rear. At least I have stops.

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Stock SY and DS. Also notice the shock alongside the CA. WTF? It's a goner.

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Tcase drop.

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This is how she looked yesterday afternoon.
To address these issues I have purchased:
UCF ultra high clearance skid and lo-pro mount.
JB Conversions SS SYE and DC DS.
Savvy aluminum adj U&L CAs
Novak cable tcase shifter
In my avatar you see a set of nerfs. My son took those for his TJ as they will be replaced with Savvy tube style rocker guards/sliders.

Got started yesterday.

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Basically just prep work as I wait for parts.

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Old 02-23-2013, 07:13 AM   #2
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Thought that was you.....gonna make it tough for me to keep up

Any chance it will be done by the 16th...heard a Rumor about another Bundy run....Of course once you have that set up I will only be able to watch since I am no locker yet and you have/ will have about 3" inches more clearance than me.

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Old 02-23-2013, 07:26 AM   #3
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Quote:
Originally Posted by jp2611 View Post
Thought that was you.....gonna make it tough for me to keep up

Any chance it will be done by the 16th...heard a Rumor about another Bundy run....Of course once you have that set up I will only be able to watch since I am no locker yet and you have/ will have about 3" inches more clearance than me.
Gonna try like heck. If not I'll have to ride shotgun with the boy. Lol. No more wrestling so I won't be able to steal his jeep again. More motivation. Told momma I'll be eating dinner in the polebarn for a couple weeks. Gonna cost me a fortune in kerosene, it's frigging cold out.
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Old 02-23-2013, 07:37 AM   #4
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Gonna try like heck. If not I'll have to ride shotgun with the boy. Lol. No more wrestling so I won't be able to steal his jeep again. More motivation. Told momma I'll be eating dinner in the polebarn for a couple weeks. Gonna cost me a fortune in kerosene, it's frigging cold out.

Yeah turned cold down here also along with snow and ice...almost like winters of my childhood. Kinda disappointed now since I usually can switch to my 3 piece combo first of March.....maybe not this year...happy wrenching!!

Hope to see ya at Bundy in March!!
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Old 02-23-2013, 01:56 PM   #5
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Ok I have the jeep safely supported by the frame. Setting front bump stops following a great write-up from UnlimitedLJ04. Tires and shocks are off. A quick search of the numbers on the shock body revealed them to be Skyjacker h7059 hydros. They measure 17" stem to eye. Are these to long for a 4" lift?
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Old 02-23-2013, 07:21 PM   #6
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Worked on her on and off today.

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Removed front springs. Tried removing by drooping axle. Not even close, so I now own spring compressors.
Measured my shocks. 17" comp 28" ext. They seem pretty long.

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Thanks to a tip from UnlimitedLJ04, I was able to replace my missing jounces and cup from a junk ZJ a half mi away for $10.

Took some rough measurements.

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With a comp shock of 17", I raised the axle until I had 17 3/4 between bottom and top shock mounts. Also tracbar is only 1/4" from diff cover. Looks a like 4" spacer will be a good starting point. Seem like a pretty big spacer.
Couple questions.
What limits front axle droop? My axle fully relaxed stops at 24" (no tires, meas at shock mounts). Still wondering if these shocks are the wrong size. Any advice would be appreciated.
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Old 02-23-2013, 07:58 PM   #7
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dunno if this will help, just did a google search on it for ya. found this on jeepfourms.:You can use the chart below to find the approximate shock dimensions needed based on lift height.


.
Shock Lengths

Front Shocks = Bottom Eyelet With Top Stud Mount
Rear Shocks = Bottom/Top Eyelet Mount


Brand/Model # Extended Collapsed Travel Position
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Monroe 32252 (* Stock) 21.25 13 8.1 Front
Monroe 37193 (* 1-3 “ Lift) 24.25 13.37 10.8 Front
Monroe 911524 (* UpCountry) 21.00 13.4 7.6 Front
Doetsch DT3350 ( 3-5” Lift) 26.5 15.5 11.0 Front
ES1000 ES124515 (* 3" Lift) 24.50 14.38 10.0 Front
ES1000 ES121515 (* 0-2" Lift) 21.52 12.72 8.8 Front
ES3000 ES324515 (* 3" Lift) 24.70 14.52 10.2 Front
ES3000 ES321515 (* 0-2" Lift) 20.24 12.45 7.8 Front
ES9000 ES921515 (* 0-2" Lift) 21.75 13.06 8.6 Front
ES9000 ES924515 (* 3" Lift) 24.70 14.52 10.2 Front
Skyjacker SJA-H7016 (* 1-3" Lift) 22.75 13.54 9.2 Front
Skyjacker SJA-H7025 (* 3-5" Lift) 24.75 14.54 10.2 Front
Skyjacker SJA-N8016 (* 1-3" Lift) 22.75 13.54 9.2 Front
Skyjacker SJA-N8025 (* 3-5" Lift) 24.75 14.54 10.2 Front
Skyjacker SJA-M9016 (* 1-3" Lift) 22.75 13.54 9.2 Front
Rancho RS5239 (* 3" Lift) 23.75 14.37 9.38 Front
Rancho RS5128 (* Stock) 20.87 13.00 7.8 Front
Rancho RS99239 (* 3" Lift) 23.75 14.37 9.38 Front
Rancho RS99128 (* Stock) 20.87 13.00 7.8 Front
Rancho RSX17317 (* 3" Lift) 23.75 14.50 9.25 Front
Rancho RSX13036 (* Stock) 20.50 12.87 7.6 Front
Bilstein F4-B46-1798 (Stock+Upcountry) 21.50 13.25 8.25 Front
Bilstein F4-BE5-6241-H8 (4” Lift)……………………………………….………….Front


Brand/Model # Extended Collasped Travel Position
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Monroe 32269 (* Stock) 21.50 13.37 8.1 Rear
Monroe 37194 (* Upcountry) 21.12 13.87 7.2 Rear
Monroe 911525 (* Upcountry) 21.50 13.87 7.2 Rear
Monroe 37029 (1-3” Lift ) 23.00 14.375 8.6 Rear
Superlift SLF-85112 (* 2-4" Lift) 24.00 14.50 10 Rear
Superlift SLF-84140 (* 3-5" Lift) 26.07 15.57 10.5 Rear
Superlift SLF-85080 (* 0-2" Lift) 21.57 13.32 8.25 Rear
ES1000 ES124509 (* 3" Lift) 24.86 14.84 10 Rear
ES1000 ES121515 (* 0-2" Lift) 21.52 12.97 8.5 Rear
ES3000 ES324509 (* 3" Lift) 24.84 14.82 10 Rear
ES3000 ES322509 (* 0-2" Lift) 22.58 13.71 8.8 Rear
ES9000 ES922509 (* 0-2" Lift) 22.58 13.72 8.8 Rear
ES9000 ES924509 (* 3" Lift) 24.84 14.82 10 Rear
Skyjacker SJA-N8058 (* 3-5" Lift) 24.84 14.82 10 Rear
Skyjacker SKA-H7058 (* 3-5" Lift) 24.84 14.82 10 Rear
Doetsch DT-3000 3265 (* 4" Lift) 24.50 14.50 10 Rear
Doetsch DT-3000 3268 (* 2" Lift) 22.50 13.50 10 Rear
Doetsch DT-8000 8265 (* 4" Lift) 24.50 14.50 10 Rear
Rancho RS5194 (* 2-3" Lift) 23.25 14.37 8.8 Rear
Rancho RS5259 (* Stock) 21.50 13.50 8 Rear
Rancho RSX13037 (* 0-2" Lift) 21.12 13.50 7.62 Rear
Bilstien F4-B46-1799 (Stock+UpCountry) 21.50 13.25 8.25 Rear
Bilstein F4-BE5-6686-H6 (4” Lift) …………………………………………….Rear


Note: * These lift heights were included where the shock lengths were found. These were the suggested shocks for that amount of lift. I have no way to ensure these are accurate.
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Old 02-23-2013, 08:19 PM   #8
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Wow. Thanks for the info. It looks like my shocks are about 4" to long.
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Old 02-23-2013, 08:37 PM   #9
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yea looks that way. thats odd. good luck with the rest. im ordering my sye this month I watched them do one a few weeks ago on extreme 4x4, looks easy enough. let me know how that goes for ya.
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Old 02-23-2013, 08:59 PM   #10
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Looks like it's gonna be a cool build I subscribed I'm interested to see the CV/SYE conversion
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Old 02-28-2013, 05:52 AM   #11
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After taking some measurements and doing some searching i found out that my shocks and my track bar are wrong for this application. The shocks are too long and the track bar doesn't have the correct bend to clear the diff cover at full up travel. Also my stock steering components are not up to the task. To fix this correctly I ordered a Currie currectlync steering upgrade, Currie TJJ adjustable track bar, and a set of 5100 series Bilstein shocks.
I did get the bump stop pads drilled and tapped for 5/16 bolts.

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This will be were the bump stop extensions attach once I get the measurements figured.
While removing my stock steering components I found this on the track bar.

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The numbers on the shocks also indicated they were Skyjacker. So I took a closer look at my springs and control arms. I did some more research and found the whole kit skyjacker. So much for the OME lift the previous owner said was installed. Oh well when I'm done the only thing left will be the springs.
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This is how she looks now with all the junk removed waiting on parts.
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Old 02-28-2013, 06:00 AM   #12
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Looking good. Good job sorting that stuff out.
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Old 02-28-2013, 06:12 AM   #13
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Looking good. Good job sorting that stuff out.
Thank you.
I did get good news, some parts came in.
These are my Savvy upper and lower control arms for the rear. Man they are stout.

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JB Conversions SS SYE.

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And my Savvy tube style rock sliders.

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For anyone wondering, this is the width of the step.

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Old 02-28-2013, 01:19 PM   #14
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Edit: Front bump stop pad holes should be drilled and tapped for 7/16 bolts.
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Old 02-28-2013, 01:48 PM   #15
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yup those shocks were way too long. that must have been the companies solution to keep the their track bar from smashing your diff...just make the shocks bottom out.

for 4" of lift, you should be around 15.5-16" compressed length shocks, which will need 2-2.5" bumpstop extension. this should work nicely with the Currie track bar clearances as well.

btw, good work so far.
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Old 02-28-2013, 02:15 PM   #16
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Good thread, looking forward to following!
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Old 02-28-2013, 04:22 PM   #17
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Gonna keep following this...but the 16th and Bundy not working for me...looks like your project is getting a little more involved than you had planned...but gonna be real nice when done...keep us posted.
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Old 03-01-2013, 06:34 AM   #18
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Gonna keep following this...but the 16th and Bundy not working for me...looks like your project is getting a little more involved than you had planned...but gonna be real nice when done...keep us posted.
Yeah I'm one of those types of people that if something's not right I have to fix it, otherwise it will keep nagging at me until do.
Since I'm held up on front end parts last night I started preparing for the SYE install. At first I had planned on removing the transfer case. I removed the transfer case skid plate and drop spacers. Then I disconnected the electrical connections to the speedometer and 4X4 indicator light. I unhooked the shift linkage from the transfer case, this will be totally removed as I am replacing it with a Novak cable. After everything is disconnecting removed there is a lot of space around the transfer case. So now I have decided to install it inside the Jeep. I will be following a write up from Stu Olson's site. http://www.stu-offroad.com/engine/jbsye/sye-1.htm I will be doing this tomorrow, its a Saturday so I can finish it all in 1 day.
I got some more parts in!
This is my UCF ultra high clearance skid and Low-pro mount.

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This thing is sweet. Now that I have it I can see I will have to do some exhaust modifications. It is an inch deep but the front and rear ends are angled up, so nothing can hang below the frame rails
Also got my Novak transfer case shifter.

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I have enough parts to finally make some good progress now. Going to get some kerosene on my way home from work as the temperatures are only supposed to be in the mid twenties this weekend. Hopefully my son and I will make great progress on this.
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Old 03-01-2013, 11:33 AM   #19
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looks like you've got a host of quality parts there. looks like a lot of the stuff i will be ordering one of these days. you'll love that novak shifter. i put mine on a couple of weeks ago and it makes shifting hot butter smooth.
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Old 03-01-2013, 04:50 PM   #20
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Looking good!
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Old 03-01-2013, 04:56 PM   #21
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You have parts I want!!
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Old 03-02-2013, 08:20 AM   #22
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Big brown was good me once again. He brought me my last major delivery.
Currie Currectlync

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Currie TJJ front track bar

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I gotta tell you pictures to not do these parts justice. I was impressed by the control arms but I'm actually amazed by the size of the track bar and steering components. it's hard to imagine the force it would take a break one of these.
Also got my Bilstein 5100 shocks.

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I only bought the front because I haven't measured the rear end yet.

And my JKS angled rear track bar mount.

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It's 25 degrees out and I got lots of parts to install. Time to fire up the salamander and get busy!
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Old 03-04-2013, 06:18 AM   #23
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Well I had a pretty productive weekend. I wanted to get the front suspension completed but it was not to be. I ran into another clearance issue on up travel. A fellow forum member has been helping me work through the front suspension. Here is a link to that thread.
http://www.wranglerforum.com/f5/fron...se-221959.html
I did install the Currie steering components.


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These pieces are much heavier and have far more flex than the stock pieces. The last thing limiting my up travel is that damn chrome diff cover. It protrudes 2 7/8" from axle housing while stock is only 2 1/8". My tracks bar is just barely rubbing on it at 3 1/4" of bump stops extension. Will be picking a stock one up at a junkyard today then I should be able to get extension down to 2 1/4".

I also got my JB SS Sye installed. These kits are way more intimidating to install the what they really are. The worst part is getting these damn little snap rings off.

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Between the write up on Stu Olsons site and JBs directions it was simple.

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You can see the difference in the length of the main shaft.

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The only problem we ran into is the JB instructions say to use a supplied new snap ring after installing sprocket and gears on the mainshaft.

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However my kit did not come with a new snap ring so I just reused the old one.
I cleaned up all the sealing surfaces is really well, applied black RVT, and put it back together.


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You will notice I have not installed the rear yoke yet. My torque wrench only goes up to 150 foot pounds and the yoke requires 200.

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Old 03-04-2013, 06:23 AM   #24
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Also my speedometer harness plugged into the JB sensor just fine. After I drive it and determine how accurate my speedometer is I may have to go with a signal converter to get it right on.
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Old 03-04-2013, 05:06 PM   #25
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Was it you're first time doing an sye? And how long it take? I've also heard beware the snap rings.
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Old 03-04-2013, 05:20 PM   #26
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i have been eyeing that ucf skid plate and tranny mount, i will be keeping an eye to see how that comes out
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Old 03-04-2013, 05:40 PM   #27
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Cool build! Many of your parts are on my wish list Seems everyone raves about the Bilstein's...
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Old 03-04-2013, 06:16 PM   #28
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Cool build! Many of your parts are on my wish list Seems everyone raves about the Bilstein's...
Thanks.
I hope those Bilstein live up to their reputation. Stay tuned and I will let you know.
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Old 03-04-2013, 06:17 PM   #29
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Quote:
Originally Posted by cbush1885 View Post
i have been eyeing that ucf skid plate and tranny mount, i will be keeping an eye to see how that comes out
I should be installing this by the end of the week.
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Frame off TJ restore project
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Old 03-04-2013, 06:27 PM   #30
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Location: MI
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Quote:
Originally Posted by PuRcELL View Post
Was it you're first time doing an sye? And how long it take? I've also heard beware the snap rings.
Yes it was. It took my son and I 2 1/2 hours. I would say if you can do your own maintenance you should be able to tackle this no problem.
I borrowed a torque wrench and put on my yokes tonight. This is a tool I made to hold the yoke.

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I put both yokes on the splines, put the transfer case in 4 hi, my son held the channel over the front yoke while I tighten the rear and vice versa.

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Frame off TJ restore project
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