Jeep Wrangler Forum banner

Tub replacement and restoration

47K views 94 replies 22 participants last post by  TheJeepKing 
#1 ·
I have a 2000 jeep wrangler 4.0. I recently swamped it out and my dad and i got it running good again, so now its time to work from top down and make it into the great jeep it can be! First off, The body is in bad shape rusting out at just about every body mount, so I picked up a new tub for just 475$ (which is a great deal!) it is rust free, the only problem with it is that the PO got in a wreck with his jeep so the front right body mount is a little off set. Other than that, which is a minor fix, it is in great shape! We are beginning to take off the old tub tomorrow and planning to work on it through the summer and put in a few new parts, along with a few mods:) ill keep a build thread and update it through the process:)
 
#3 ·
This is what we started with.

View attachment 272817

2000 Sport 4.0. Looks good in the pic but has a bad case of Michigan cancer. Picked up a southern 03 Rubi tub off CL for $475 so its time for a change.
Removing front clip.

View attachment 272822



View attachment 272820



View attachment 272821

Removing steering column and dash.

View attachment 272823



View attachment 272825

Chassis with old tub.

View attachment 272829

Chassis with new tub.

View attachment 272828

As you can see the tub was shot. All body mounts were rotted out.

View attachment 272837



View attachment 272841

We restored the frame last summer.
Stay tuned, TheJeepKing will outline some of the upgrades we will be doing during this project. BTW he is my 17 year old son. :)
 
#6 ·
While we have the tub off, we figured now would be a good time to replace any parts that need it. We took out the transmission today so we can put in a new clutch. We are also putting in a new power steering gear because the one we have now leaks-_- we plan on taking the frame down to bear metal and painting it all in rustoleum bed liner to prevent it from rusting. The whole tub is also going to be painted in bed liner, I like the way it looks(; while the tubs off we're replacing any bushings that are worn out. Finally, we are ordering Metalcloak arched tube fenders and 6" fender flares to prepare my jeep for eventually running 35's and a lift.
 
#12 ·
Progress is slow because because I'm working 7-12s and the JeepKing works 40hrs plus football and other teenager things.
We did manage to test fit the new tub to the chassis.

View attachment 276641



View attachment 276642

Just wanted to be sure nothing changed in the body mounts between years. Everything lined up good. A few differences we have found are the sport bar mount flanges on the windshield supports are wider on the late model (LM), the hole for the lower shift boot is larger LM, and the rear seats mounts are different. Jeep must have changed the HVAC at some point because the passenger side fire wall EM has a hole for the blower motor

View attachment 276644

and the LM doesn't.
We will need to make a template and make our own hole with the plasma cutter.
 
#13 ·
Progress is slow because because I'm working 7-12s and the JeepKing works 40hrs plus football and other teenager things.
We did manage to test fit the new tub to the chassis.

Just wanted to be sure nothing changed in the body mounts between years. Everything lined up good. A few differences we have found are the sport bar mount flanges on the windshield supports are wider on the late model (LM), the hole for the lower shift boot is larger LM, and the rear seats mounts are different. Jeep must have changed the HVAC at some point because the passenger side fire wall EM has a hole for the blower motor

and the LM doesn't.
We will need to make a template and make our own hole with the plasma cutter.
Damn app.

Land vehicle Vehicle Car Automotive tire Jeep




Land vehicle Vehicle Motor vehicle Car Jeep




Vehicle Car Auto part Engine




Automotive exterior Vehicle Bumper Auto part Car
 
#14 ·
Cool thread, lotsa work ahead but looks like you are nailing it out. A couple suggestions. Por 15 would be a great product for the frame to prevent rust. As much Berliner as you are planning on doing, you would save a ton of money and time buying a kit that comes in gallons or quarts with a gun to spray it. There is a company or two in the vendor section advertising their products. Good luck and looking forward to more.:popcorn: :thumb:
 
#23 ·
Had a good day yesterday. We both finally got a day off together and were able to work on it.
We took the old coil bucket and removed the rusted mounting flange. Then took the original coil cups and welded them to 7" round X 1/4" plates.
 

Attachments

#24 ·
We then welded 1/4" plates on each side of the frame rail. The new coil buckets were welded to these. Everything was wire wheeled and painted.

Auto part Vehicle


This picture shows how extensively we had to repair the frame.

Vehicle Motor vehicle Automotive exterior Chassis Automotive tire


Some of it is using Safety Cap pieces and some pieces we have fabricated. Today we're going to fabricate frame tie ins for the rear bumper then the frame should be complete.
 
#26 ·
Frame is completed. All fabrication is done. The whole thing was stripped to bare metal, primed, and sprayed with several coats of Rustoleum bed liner. Took about 4 cans of BL.

Land vehicle Vehicle Automotive tire Tire All-terrain vehicle


We have to replace the front axle ujoints, install the new steering gear, trans and gas tank then the chassis will be finished.
 
#27 ·
We were gonna install the trans today so we could finish the the exhaust. Of course when I removed the clutch bearing arm the retainer spring broke. Had to order from dealer.
So we started prepping the tub. As mentioned earlier the LM tub is lacking a couple holes necessary for the EM parts. We made some templates and JeepKing cut the holes in the firewall with the plasma cutter.

Mechanic Automotive exterior Vehicle Auto mechanic Panel beater




Automotive exterior Bumper Auto part Vehicle Fender


Grinding smooth.

Motor vehicle Vehicle Car Automotive exterior Bumper


Fit perfectly.

Auto part Bumper Automotive exterior Vehicle


Now that the mods to the tub are complete it's prep and bed lining.
 
#28 ·
I recently upgraded to 35 MT/RKs on my rig so swapped my lightly used 33" Duratracs for his lightly used 31" Duratracs. I sold the 31s to a forum member.
To clear the 33s he will need flat fenders. We were originally gonna use Metalcloaks but this build is being done on a 17yro with summer job budget. We were able to get a pair of Smittybilt :)0) XCR no flair tube fenders for $300 shipped from Baseline 4X4.
He also bought new unit bearings and Spicer 5X760 ujoints for the front axle. The rear axle (he's lucky...D44) pinion seal is leaking and the yoke is grooved so he bought a new yoke and seal.
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top