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Old 11-22-2011, 08:03 AM   #1
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My 2004 Rubicon Build

I started out with a pretty much stock 2004 Rubicon. Previous Owner had added a volant air intake and some cometics. I have added seat covers, new bumpers, a warn winch, OME Steer Stabilzer and Euro light gaurds. The next process will be to install by DPG-Offroad Ultimate TJ lift kit.

DPG Kit includes:
-Old Man EMU 2.5" Lift kit
- 4 New Coil Springs
- 4 New Nitro Shocks
- DPG Bumpstop Kit
- JKS 1.25" Body Lift
- Brown Dog 1" Motor Mount Lift
- JKS Quicker Disconect Sway Bars
- JKS Adjustable End Links
- JKS Adjustable track bars (Front and Rear)\
(Since I have a Rubicon no T-Case change is needed)

All of this will be installed so that I can run my new 33X12.50 Duratracs on 15x8 DC-2s from Mr Richard (D**K) Cepek

I will post pictures as go through the install. It will probably be a week or so before I can really get going with it. I wanted to do it over the holiday but other matters are calling me away.

So here are the first rounds of pictures.

BEFORE
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Old 11-22-2011, 08:06 AM   #2
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Good lookin' Rubi! Looking forward to seeing it get taller. You've got a pretty good kit to work with. But before you get started, read through the instructions and verify you have all the little parts needed, understand what is going where, and have the tools you need.

Like I said before, you have questions or problems, let me know.

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Old 11-22-2011, 08:11 AM   #3
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Steering Stabilizer, Spark Plugs, and Bumper install:

Steering Stabilizer, Spark Plugs, and Bumper install:

Went with the Best Top HighRock 4x4 bumpers front and back. Winch is on order and I will be getting some new fog lights to mount in the next month or so.

Fun parts. Getting the old Steering stabilizer off was a challenege. You def need a big hammer!!

Taking off the trailer hitch also required my imapct gun to get the old bolts to break loose.

On the bumpers....they are pretty heavy and not super easy to hold alone. The real pain was the fact that the frame in the rear and in the front were discolored so I had to paint them before I could finsih the install. I also went ahead and painted the exhaust with High Heat paint as well. It was looking worn.

The front bumper used the existing hardware. So I had to paint all the star and other bolts flat black so they would blend in with the new bumpers. Check the pics there are before, during, and after.
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Old 11-22-2011, 08:13 AM   #4
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Steering Stabilizer, Spark Plugs, and Bumper install Cont:

Steering Stabilizer, Spark Plugs, and Bumper install Cont:
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Old 11-22-2011, 08:17 AM   #5
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Very clean
I have a Rubicant
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Old 11-22-2011, 08:17 AM   #6
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Winch and Euro Gaurds

Winch came in and got added to the mix. Also put Euro Light guards on the front and Back.

Winch was damn heavy. I had to take the front bumper back off of the jeep to mount the winch. did it all by myself then had my Girl help me carry the bumper/winch combo back out and set it on the front frame.

Then I hit the first snag. One of the bolts on the bottom of the frame woudl not go back in. Had to pull out the tap and die set and re-tap the threads.

After that all was easy. i ran the winch wires to the batter terminals, a few zip ties to control the wires and all done.

The Euro guards went on easily. Again I had to paint stock hardware black so that it blended into the black of the guards.
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Old 11-22-2011, 08:19 AM   #7
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Everything is Here!!!

Tires and wheels came in last night and I now have all of the parts for the lift kit. Hopefully I will get to start on the motor mounts and body lift this coming Sunday!!

Here's a pic of all the stuff I have left to put on.
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Old 11-22-2011, 09:05 AM   #8
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You will want a second set of hands for the MML. Trust me. And a floor jack.

Winch was a good choice - 9.5ti?

How much work was required for the steering stabilizer? Mine is still stock, and thinking about going with the OME since my lift is OME. I just haven't gotten around to replacing it yet.
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Old 11-22-2011, 10:32 AM   #9
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Yup its the 9.5ti.

And the Stabilizer wasn't much work at all. The hardest part was getting the stock one off. If you look at the picture, the bolt on the right side of the stock stabilizer was a pain to get out. Had to bang the crap out of it with a big framming hammer. At first I was worried about bending something, so I looked it up and on every forum the consensus was bang the crap out of it with a BFH. Other than that its very quick and easy.

The one thing I did find is that its very easy to over tighten the bolts. It will probably work ok if you do over tighting but you will def wear out the bushing faster that way.

They do make a HUGE difference. You really won't appreciate it until you're going 70 down the highway and hit a big bump. With the stock stabilizer the wheel gets jerked all over the place. With the OME it just gives a little bump fairly equvilalent to what a sedan would do.
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Old 12-05-2011, 12:36 PM   #10
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Next Step - 1.25" JKS Body Lift & 1" Brown Dog Motor Mount Lift

OK...so I final got some time to work on the Jeep again this weekend. I thought I would quickly knock out the body lift and the Motor Mount lift.

Body lift took me a little less than 2 hours start to finish. I was qorking fast and a buddy stopped by to talk to me for a but while I was doing it. Everything went on well. I did have to remove the passenger headlight to to pull the grill mount on that side up to pop into place.

It was a good thing I removed the bezel around my fuel filler, It ended up being about an 1" short. Had to take it off, get new hosing and lengthing it to get it to fit back into place properly. Pain in the butt getting that thing loose from the gas tank. Banged my elbow pretty good when it finally came loose.

The one thing I have noticed is that the passenger side pucks look like they are being compressed more than the Driver side. I tourqued both sides to 31 foot pounds. Has anyone seen this before? I would like to know if its somehting I can fix, or if I just have to live with it. Please see Picture of rear of jeep. You can def see the differnce in the picture.

Next task was the motor mounts. I took the tranny mount loose from the skid plate and started jacking up the engine. Passenger side mount was super easy no issues. Driver side was a little more difficult but I knew that was coming since I have A/Cl. I lossened the mount where it connects to the block which gave me enough room to wiggle the through bolt out of the existing mount. Tightened it back up and install the new mount with no further issues under the hood. then I let the engine back down and the fun started.

The tranny mounting bolts would not go back into the holes in the skid plate. I made multiple attempts jacking it up and down trying to get them aligned. I finally had to loosen up the skid plate and shimmy it all around until I finally got the bolts back through the plate. Then I bolted the plate back up and then snugged up the tranny mount bolts.

Test Drive - Everything seems to be working fine. The changes I noticed are as follows:
- Stick is at a slightly differnt angle now.
- No change to 1st, 3rd, and 4th gears
- 2nd and 4th gear are both a little tighter going in

Anyone know what if there is anything I should change to get the gears inline better??

Also test mounted my fog lights and snapped some pics.
-
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Old 12-05-2011, 12:44 PM   #11
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Looks good inside and out. Really impressed with your Rubi!
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Old 12-05-2011, 01:16 PM   #12
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Thanks!! I'm getting there. Once I get the suspension lift in I think I will be take a little break and jsut drive and wheel it.

Of course I say that now, I need to flush teh cooling system and change out all the fluids(Tcase, diffs, etc) and if I'm going to drain the diffs I might as well put new covers on them so I don't have to do it twice!!
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Old 12-06-2011, 07:55 AM   #13
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That is one CLEAN Jeep!! I am happy to see the stack of high quality parts you are installing. You will not be disappointed with that OME/JKS setup you're going with. Are you planning to carry a full size spare? Did you look into Bestop's new bumper/tire carrier?
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Old 12-06-2011, 10:09 AM   #14
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Thanks Patrick. I am going to carry a full sized spare. I'm going to see how it works on the stack spare mount first. If I go with a tire carrier I might have to get bigger rear springs.

Can anyone comment on the Body lift issue I have? I think I may just create a new thread on that issue.
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Old 12-06-2011, 06:30 PM   #15
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Looking great!!!

As for the lean, I'm willing to bet you have a puck or two upside down or not mounted quite right. The two directly under the tub by the upper shock mounts are VERY intimidating. I'm willing to bet one of them ( drivers side is my guess) is upside down.
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Old 12-06-2011, 08:48 PM   #16
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Thanks! Im sure none of the pucks are upside down. I will go back and check and make sure all of them are seated properly. Maybe one of them shifted a little before I tightened them down. I figured if they have a bolt through the middle of them they can't move around too much. I am thinking about jacking the passenger side back up and resetting all the pucks and then hitting it with the torque wrench again to make sure I didn't get them too tight.
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Old 12-13-2011, 12:55 PM   #17
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So last Friday I decided to lift the body up again and reset all of the pucks. They all looked to be situated well but i adjusted and repositioned each one anyway. When I retourqued the bolts I did the passenger side slightly less that the driver side. I measured the space between the body and rear frame/bumper and the difference is now 1/16 of an inch. I think I can live with that.
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Old 01-09-2012, 12:54 PM   #18
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Lift kit is now on

So the Wednesday before Christmas the Jeep went up on stands. The first day I had to work on it was after New Year. After a few days of working on the Jeep when I had the opportunities the entire lift kit is finally on!!!

I went ahead and changed out the diff covers and fluid since I had it up in the air and also changed the T-Case fulid and the tranny mount. Also did a little bit of painting. I painted the space between and frame and body made by the body lift black. Also painted the area under the tailgate black so the body lift doesn't show as much.

Got the trackbars in and everything somewhat aligned, come-alongs and a measureing tape can only do so much. Had to tighten up the front discos after the test drive, definetly had them too loose for street driving.

Now its got to go in for an anlignment and look over by the pros and I need to straighten out the steering wheel.

And here are some pics from the last month, first batch is when it went up before Christmas:
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Old 01-09-2012, 12:55 PM   #19
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Pics During

Here are a few during the install, these are with all the old stuff off the front and back. Notice the hole is drilled on the passenger side to install the bump-stops in the first pic:
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Old 01-09-2012, 12:57 PM   #20
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The Lift is ON!!!

And the final product!!
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Old 01-09-2012, 12:58 PM   #21
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A few More

She wanted to take it on the FIRST DRIVE! I let her ride along
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Old 01-09-2012, 01:01 PM   #22
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Before and After

Here are the side-by-side before and after shots.
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Old 01-09-2012, 01:05 PM   #23
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Couple more before and after

More Before and after:
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Old 01-09-2012, 01:14 PM   #24
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Looks great, nice and clean! I have an 03 rubicon, but we beat them to death up here in New England...LOL...
don't try to mount the full size spare on the tailgate holder. It won't take the strain and you end up with skewed hinges that are NOT adjustable. Ask me how I know...I bought a swing away tub mounted tire carrier...and kind of wish I had taken the plunge and got a bumper mount instead. But you won't need new springs to hold that tire up-because of the winch on the front end, the tire will actually help to level the rubicon out a bit.
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Old 01-09-2012, 01:18 PM   #25
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Thanks!

I was kinda wondering if the spare would last there. I actually think the 33x12.50 on the 15" DC rims are lighter that the 16" Moab with the Load E MTR. If it does do anything to the hinge it must because of its overall size and how the weight is distributed.

Plus my garage door came down on the open tailgate a couple weeks ago and it hasn't closed quite the same since
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Old 01-09-2012, 01:21 PM   #26
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Looks really good!!!

What you doing with the Moabs?
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Old 01-09-2012, 05:39 PM   #27
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I have a bunch of stuff in my garage that needs to be sold. I have 5 moabs with Load range E MTRs on them. 1 Brand New the others with about 30% tread left. The stock bumpers, grille guard, tow hooks, fog lights, a full soft top, a washer and dyer, a front door

I'm willing to ship them if your willing to pay for it
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Old 01-09-2012, 07:38 PM   #28
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Looks good ,Iam doing the same in time . Do your diff covers hit on anything,what cover did you use in the rear i could not tell in your pictures. again good looking....
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Old 01-10-2012, 07:53 AM   #29
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The covers don't hit anything. I did switch the JKS adjustable track bars in the front and rear. I used the same D44 ARB Cover on the front and the rear.
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Old 01-10-2012, 08:52 AM   #30
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Looks good!! I plan on doing the same OME/JKS pretty soon.

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