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Old 05-07-2014, 02:47 PM   #1
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Kdilly's TJ build

Allright, so I have been meaning to start my build thread for a while now. My jeep was a gift to me from my grandparents/parents for high school graduation. Bought her in March of 2012.

Can't find my pictures from when I brought her home, so here's some of the earliest ones I can find:









How it came:
2002 Sport
NV 3550 Manual Transmission
Hard and Bikini tops
D44 Rear axle
3.73 Gears
2 Inch skyjacker BB
Skyjacker Shocks
TC Drop (1"?)
1"BL
Cheap radio shack CB with Antenna
16" Rubi take-off wheels
285/75/R16 Pro Comp M/T's (~33")
Cowl Air Intake

What I have done so far:
Aussie locked the front D30
Rebuilt Transmission
LED Rock lights
JCR Front Bumper with Stinger
Smittybilt H20 8k Winch

Right now, I am a student at A&M, so I have a very limited budget and very limited time to install mods. So while I am at home this summer, I will be busy working and buying/installing upgrades for the jeep.

Future (in no order):
MC 3.5" Dual Rate Springs OR OME 2" Springs. Haven't decided yet
Rancho 9000 XL
Antirock F/R
MC Adjustable CA's
Monstaliner
SYE/CV
Vanco Big Brakes
Heavy Duty Tie Rod/Drag Link
Regear to 4.88s
35's
Rear Corner Armor
Tera 2 LO kit
Currie or MC track bars

Plans After College:
WB Stretch
Triangulated 4-Link Rear
37's
Custom Roll Cage
Keep it Street Legal to be a DD
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Old 05-07-2014, 03:00 PM   #2
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Bout time you started a thread. Sucks that you'll be back north for summer.

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Old 05-07-2014, 03:04 PM   #3
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Bout time you started a thread. Sucks that you'll be back north for summer.
Yeah, but back north I have all the tools and garage space I need for my plans this summer
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Old 05-07-2014, 03:10 PM   #4
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I do miss having all that.
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Old 05-08-2014, 02:51 AM   #5
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There were some goodies waiting for me when I came home yesterday!









Put the Brake/Reverse lights on tonight (just finished)

Need to get some of those LED bolts for the license plate lights.

With these lights, I was unable to reuse the stock license plate mount.

Need to get an EP-26 to fix my fast flash but I don't mind it for now.

Also, it looks like theres some rust on the tailgate, but it's just dirt from where the spare carrier was. Leaving it off for now because I like the look.






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Old 05-08-2014, 08:41 PM   #6
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Eagles unite!! Lol, became one last December. Anyway, did you have to do anything with the evaporator for the gas tank after cutting for the tail lights. I heard that could be a problem sometimes.
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Old 05-08-2014, 10:15 PM   #7
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The evap canister is under the hood with the 2002.
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Old 05-09-2014, 12:18 AM   #8
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Eagles unite!! Lol, became one last December. Anyway, did you have to do anything with the evaporator for the gas tank after cutting for the tail lights. I heard that could be a problem sometimes.
Yea! I got mine in November of 2011.

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The evap canister is under the hood with the 2002.
Yes, that's right. I will have to do some relocating when it comes to installing the highline fenders though. Going to have to get creative with the arrangement of the washer bottle, evap canister and fuse box. A new battery tray comes with the fenders to help there.

Plan is to drop them off at the powder coaters early next week after I call around and get a couple quotes.
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Old 05-09-2014, 08:33 AM   #9
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I am in the process of installing the 'negative flare' version of those XC fenders. The fenders and inner fenders are in place, I am just working on getting everything mounted. I had the PSC battery bracket powdercoated, along with the factory battery tray.....it was a mess! The fuse box won't be hard to mount (just remove the metal bracket and bolt the box straight to the fender), but the evap canister is the real issue.
For the washer bottle, I picked up a small, universal setup that will fit just about anywhere. I didn't want to have to try to remount the factory bottle along with everything else. It gets tight in there!
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Old 05-09-2014, 09:19 AM   #10
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I love those tail lights, time for a new rear bumper now though.
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Old 05-09-2014, 11:33 AM   #11
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I love those tail lights, time for a new rear bumper now though.
Yeah, all with time. A rear bumper isn't too high up on my list. Next up will probably be a ucf skid and sye/cv. I really want to get rid of this transfer case drop.
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Old 05-09-2014, 11:37 AM   #12
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I am in the process of installing the 'negative flare' version of those XC fenders. The fenders and inner fenders are in place, I am just working on getting everything mounted. I had the PSC battery bracket powdercoated, along with the factory battery tray.....it was a mess! The fuse box won't be hard to mount (just remove the metal bracket and bolt the box straight to the fender), but the evap canister is the real issue.
For the washer bottle, I picked up a small, universal setup that will fit just about anywhere. I didn't want to have to try to remount the factory bottle along with everything else. It gets tight in there!
Awesome! Thanks for the advice. I will probably end up extending the hoses and moving it somewhere completely different. I guess I will be ordering a new washer bottle too!
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Old 05-09-2014, 05:10 PM   #13
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This is the bottle I have.


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Old 05-10-2014, 02:15 PM   #14
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Dealing with a little bit of a set back. Yesterday, my brother got his jeep stuck and called me to winch him out.

I winched him out and tried to back out of this little ravine but one of my back wheels was spinning. Note: I didn't have 4WD because I bent my driveshaft on my last wheeling trip over spring break. So long story short, I gave it a little too much gas and *POP*

I ended up getting unstuck and drove (limped) it the two miles or so back home. But any time I would accelerate, I heard a popping noise

I knew it right away, thought it was an axle shaft. So I removed the drivers side axle shaft last night and it's fine. Next, I popped the Diff cover. All looks fine until I noticed there are chunks out of a couple of the spider gears. So I am about to go pull the other shaft and remove the carrier to assess the damage fully, but for right now my R&P look fine.








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Old 05-10-2014, 05:46 PM   #15
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This is the bottle I have.


Where did you order it from and are you using the same pumps that were attached to the old one?

I did a quick google search yesterday but couldn't really find what I was looking for.
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Old 05-11-2014, 01:12 PM   #16
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While my jeep is immobile, I got the hood and one fender off so far. Fenders go to the powder coater on monday.

I removed the carrier and have about 4 chips in each spider gear. From what I have seen, rebuild kits are about $250 for the differential, so I am probably just going to get a locker for a little bit extra. Kind of an impromptu upgrade, but my Jeep won't be driveable until I fix it and I'm pretty excited about it.


I have been doing my research on lockers for the rear. I have ruled out the aussie(drivability), ARB (price = $1000+) and OX cable actuated(bad reviews). Since my jeep is going to be driven long distances back and forth to College Station, I will need it to cooperate on the road. My top two right now are the detroit Locker and the Eaton E-locker. Any thoughts or alternatives? Cavasar, I know you reccomended the Yukon Zip locker but those are $800 plus an OBA compressor. I can get the Detroit for $650 on Q-tec or the E-locker for around $800
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Old 05-11-2014, 10:19 PM   #17
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. Since my jeep is going to be driven long distances back and forth to College Station, I will need it to cooperate on the road. My top two right now are the detroit Locker and the Eaton E-locker. Any thoughts or alternatives? Cavasar, I know you reccomended the Yukon Zip locker but those are $800 plus an OBA compressor. I can get the Detroit for $650 on Q-tec or the E-locker for around $800
WHOOP!

I don't have any experience with any rear locker. I just ordered the Detroit for the rear because of the great reviews, the difference being mine is an auto and yours is standard.
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Old 05-12-2014, 09:00 AM   #18
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Where did you order it from and are you using the same pumps that were attached to the old one?

I did a quick google search yesterday but couldn't really find what I was looking for.
It has a built-in pump. I got it off ebay, but I can't find a current listing for it. Type 'universal windshield washer bottle' and you will have countless options, most being pretty small and including pump.

Oh, and for lockers....my axle guy is a big fan of the Yukon zip locker. I have an ARB in my 8.8, but have not hooked it up yet.
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Old 05-15-2014, 08:28 AM   #19
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When did you add that picture about the spider gears, bummer. You were getting ready to regear anyways right?
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Old 05-15-2014, 12:08 PM   #20
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When did you add that picture about the spider gears, bummer. You were getting ready to regear anyways right?
Lasr Friday. Im still trting to decide what I want to do about it. I called around and the cheapest quote I got was $1800 with no lockers. Where did you have yours done?

Its a predicament because I dont want to pay for a locker twice (once now, once after regear) but I dont have $2k lying around for a regear
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Old 05-15-2014, 03:56 PM   #21
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Just broke down and bought the detroit locker. I will be picking it up from 4WP tomorrow and installing. It was either $300 for a trac-lok rebuild kit or $500 for a locker so I went with the locker.

It just sucks to know that I will be buying a new locker when I regear in the future because the detroit is for 3.73 and down.

Fenders will be dropped off at powder coaters tomorrow and driveshaft will be dropped off to get re-tubed.
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Old 05-17-2014, 08:45 AM   #22
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I'm having mine done at Addictive Autoworks in Calvert at the beginning of the week when my guy gets back from Go Topless Day. Not sure on cost per axle as I'm having several things done at the same time. You'll be buying a new locker but at least you can re sell you the one you just bought.
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Old 05-17-2014, 01:16 PM   #23
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I'm having mine done at Addictive Autoworks in Calvert at the beginning of the week when my guy gets back from Go Topless Day. Not sure on cost per axle as I'm having several things done at the same time. You'll be buying a new locker but at least you can re sell you the one you just bought.
Yeah, I guess I will just be a slug on the highway for a while. The drive from here to cstat will probably take like 5 hrs now instead of 4 lol.

I should have the locker soon, and fenders are being powdercoated this weekend. Hope to have everything done before next weekend. I still have to cut the hood and relocate the evap canister and such.
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Old 05-21-2014, 12:08 AM   #24
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Any updates? Got my ECGS package today, just waiting on the shop to fit me in. Kind of short notice but I'm going to Hidden Falls on the 7th if interested. Just enough time to break in the new gears.
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Old 05-21-2014, 12:21 AM   #25
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Any updates? Got my ECGS package today, just waiting on the shop to fit me in. Kind of short notice but I'm going to Hidden Falls on the 7th if interested. Just enough time to break in the new gears.
I would love to go the 7th if I can get everything installed in time. I'll get back to you on that.

Got a couple phone calls today. My driveshaft is rebuilt and my fenders have finished being powder coated. I am going to pick them up tomorrow. Then I have to cut the bottom few inches off the hood, install the new LED turn signals and get the fenders bolted up and all the components relocated.

My locker came in yesterday. I just got to working on it tonight and I found out it doesn't come with new carrier bearings. I have to get new ones AND the worst part is I am basically setting up a R&P since the carrier is being replaced. So I have to get the preload, backlash, etc. just right. I may even have to order a few shim packs to get the preload right.

My next steps:
  1. Get old carrier bearings off with some special puller, or see if I can pay someone like $20 to do it with their puller (they are expensive)
  2. Buy new bearings
  3. Take the shims off and put them on the new carrier
  4. Test fit new carrier, check preload, mesh pattern, backlash, etc.
  5. If everything isn't right, order more shims and try until it's right
  6. Install carrier
  7. Reassemble Everything

So yeah, I have my work cut out for me for now. BUT hopefully I will be done by the 7th so I can go to HF.
The hardest part will be getting the gears set up. Youtube will be my guide haha
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Old 05-21-2014, 05:22 PM   #26
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Picked up fenders and rebuilt DS today

Also got the carrier bearings pulled for $25 at a local shop.

Pics:




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Old 05-21-2014, 10:43 PM   #27
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Fancy Fancy, if you need any help with the front end I know a guy in NRH who does good work.
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Old 05-22-2014, 12:48 PM   #28
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Got the first fender on



Carrier with bearings pulled:


Detroit with ring gear bolted on
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Old 05-22-2014, 03:22 PM   #29
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Old 05-22-2014, 08:33 PM   #30
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Let me know if you need any close-ups on what I did with the underhood accessories. It actually turned out much easier than I was letting myself think.

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