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Old 07-17-2014, 11:14 AM   #1
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The Black Stallion

I figured now was the time to start my build thread as I am finally doing some building. I will try to keep things updated as much as possible as I plan to use this as more of a journal to see my baby grow. I'll also try to keep a recent picture here at the top:

/| ,[_____],
|_|_| [ºIIIIIIIº]
()_)--()_)--o-)_)

I bought the stallion about a year and a half ago. A black 2000 TJ Sahara with four inch springs and 33s. Not much else had been done to it, or at least that's what the PO claimed.

Since then I have mostly fixed things that were either done wrong, not done at all, or broke prematurely.
  • Rebuilt NV3550
  • Transmission mount
  • Heater Core and AC Evaporator
  • Sway Bar Links

And added a couple of things:
  • Neoprene Seat Covers
  • Quadratec Nerf Bars

The plan changes and evolves as I learn more and more about the capabilities of the Jeep and what I want to do with it. I have a very long list of long term mods, short term mods and immediate mods and I'll update them as time goes.

Immediate (the foreseeable future and/or items already purchased waiting to be installed)

Suspension:

Currie Poly Adjustable Bumpstops
Metalcloak Adjustable front track bar
Metalcloak dual adjustable aluminum control arms with Duroflex joints

Drivetrain

Dana 30 Axle shaft u-joints and ball joints
RuffStuff 3/8" Dana 30 Differential Cover with Lubelocker
JB Conversions HD SYE
AW4 conversion
Transmission Crossmember
Denny's Driveshafts front and rear driveshafts

Short term (within a year, maybe two)

Ultimate Currie Steering Kit
Fabricate Rocker Armor
Fabricate Front Bumper
Barnes 4WD Rear Bumper
Skid Plate(s)
3 or 3.5" springs
1.25" BBL
1" MML
Tummy Tuck
35" Tires

Long term (the wishlist)

HP30 Front Axle
Dana 44 Rear Axle
4.88 gears
3-Link Front
4-Link Rear
Metalcloak or Poison Spyder Front Fenders
Savvy Aluminum Rocker armor
Savvy Corner Armor
100" wheelbase
Custom Rear Cut
Fuel Cell
37" tires
OX Lockers front and rear

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Old 07-17-2014, 11:34 AM   #2
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build sounds pretty awesome, excited to watch it!

what type of wheel do you normally do?

and throw up a pic!!!

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Old 07-17-2014, 12:27 PM   #3
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I go on trail rides and try to hit the rocks and other obstacle courses. My goal is to have a rock crawler with a relatively low center of gravity.

I have to get a recent picture. Everything I have is about a year old.
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Old 07-21-2014, 10:18 AM   #4
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Not much in terms of wrenching, but got myself a new pinstripe down the passenger side of the jeep.

Click image for larger version

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And building some shelves to make some room in the garage.

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Old 07-31-2014, 10:17 AM   #5
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It looks like the AW4 swap time is upon us. Next week is a slow week at work and I'll take some time off to do the bulk of the swap. The rest will be done while I wait for drive shafts.

I should be picking up my transmission and TCM tomorrow so I can start on the wiring harness.

New to me shelves will go up this weekend to finish organizing my garage and I'll hopefully have everything ready for surgery.
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Old 07-31-2014, 01:03 PM   #6
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Your build is basically what i want to do with mine, rock crawler but not too big. Looks good other than the key mark, that sucks...id love to see someone key mine, that'll be the day i go to prison lol
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Old 07-31-2014, 03:10 PM   #7
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Quote:
Originally Posted by Cole Man View Post
Your build is basically what i want to do with mine, rock crawler but not too big. Looks good other than the key mark, that sucks...id love to see someone key mine, that'll be the day i go to prison lol
It wasn't a key, it was a tree branch or some other element of nature. I went wheeling the night before with a couple of buddies and the trails we were in were a bit tight. Interestingly enough, the JK I was following did not get any scratches like that.
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Old 08-05-2014, 09:29 AM   #8
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Well the garage is finally cleaned out and I have plenty of room for the AW4 swap. The Jeep is going in for surgery today.
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Old 08-05-2014, 07:43 PM   #9
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How much did the heater core run you? I have a leak in mine which is a pain in the ass!
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Old 08-05-2014, 09:16 PM   #10
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How much did the heater core run you? I have a leak in mine which is a pain in the ass!
The core itself was only about $70 from Napa. I changed the AC evaporator while I was I. There considering how much of a pain it is to gain access to the heater core. the evaporator was about $100 if I remember correctly.
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Old 09-11-2014, 01:23 PM   #11
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So I've been busy doing the swap and not a whole lot of time to post. Here's a few pictures of the progress, which is a bit slower than I would like.

The transmission on the way home:


Empty tunnel:


Tranny where it sits today waiting for the buyer:


More random shots of the disassembly:






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Old 09-23-2014, 07:32 AM   #12
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...and here's the prep process.

Reclocking transmission:





Cutting the transfer case input:







Fits like a glove:

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Old 09-23-2014, 07:37 AM   #13
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The SYE.

Before:


After:



Side by side:

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Old 10-03-2014, 07:32 PM   #14
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Finally all done. I'll post more pictures soon with the assembly process.
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Old 10-03-2014, 08:07 PM   #15
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jb conversion super shorty sye's rock.
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Old 10-03-2014, 08:18 PM   #16
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Yeah it does. Even with the AW4 added length I still have a longer driveshaft than the other guys with SYEs around here. Then again t-case drops are common practice around here.
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Old 10-24-2014, 04:02 PM   #17
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I just realized how long it has been since my last update. Will add up the rest of the pictures tonight. The AW4 is working great and so far have received many compliments on the installation.

Now I need to move on to working on the D44 rear axle I bought earlier this year (or was it last year?). Hopefully the housing is still useable and if so, I'll get it regeared and put on. Then an HP30.
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Old 10-27-2014, 10:50 AM   #18
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Transmission going in:


Harness:






Transmission Cooler:


Transmission Mount:

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Old 10-27-2014, 11:06 AM   #19
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A few extra goodies installed as part of the upgrade:







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Old 10-27-2014, 11:33 AM   #20
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And finally how it looks on the inside



And its first time off-road after surgery.

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Old 11-02-2014, 10:03 AM   #21
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So far the transmission has been working great. Now that the temperature is dropping outside I'm a bit concerned about the transmission temperature. It seems to be taking a while for the temperature to raise above 100degrees.

I didn't run the lines though the radiator like OEM installations do and now I'm wondering if I should have.
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Old 11-18-2014, 07:25 PM   #22
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Not much to say as of late. Helped a buddy of mine get his rig back on the road after his driver side front u-joint have out and destroyed the axle shafts. Decided to look at mine just for safety sake and my passenger side is on its way out. I guess I know what I'll be doing this weekend. Good thing I have them at the ready already.

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