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Old 06-21-2014, 02:13 AM
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Detail Oriented

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Holton345's Avatar
Join Date: Jun 2013
Location: Yazoo City, MS
Posts: 3,170
Rebuilding Strategy?

I posted this and wondered why I was getting no responses. Then it was pointed out to me that I was in the YJ Forum. WHOOPS!

So here we go again...

I have ordered all of the following for my 2003 Sport (4.0L, D44/D30, 5 speed):

Metalcloak 3.5" suspension kit (OME shocks, double-ended aluminum arms)
Teraflex super short SYE
Tom Woods driveshaft
Novak TC cable shift linkage
Black Magic Pads
Centric premium rotors
Synergy ball joints
Timken HA597449 unit hub bearings
Spicer 5-760x universal joints

I also have a slow leak in my rear D44 pinion seal.

I am trying to tease out an install order for all this stuff.

Here is what makes sense to me. Please chime in if you can see any more efficient way to do this.

Brace up transmission and transfer case with a ratchet strap or tranny jack.
Remove the transfer case skid.
Wire brush minor surface rust till I get to shiny, bare metal.
Paint bare metal parts of frame rails.
Clean up skid and repaint in same manner as frame.

Remove rear driveshaft.
Remove rear pinion yoke.
Drain differential and clean.
Install Lube Locker and diff cover.
Replace leaking seal.
Fill with new gear oil.
Install yoke.
Clean and paint rear axle.

Service front differential and install new Lube Locker.

Install SYE.
Install Novak kit.
Paint new driveshaft.
Install new driveshaft.
Install TC skid with one washer per bolt so water can dry between surfaces.

Tear down front wheels.
Clean and paint axle and knuckles.

Replace ball joints.
Replace U joints.
Replace unit bearings.
Replace rotors.
Service/clean calipers.
Paint calipers.
Replace brake lines with longer ones from lift kit.
Replace pads.
Service brake fluid system.

Install lift kit as per Metalcloak's instructions, except for the brake lines.
Do alignment.
Re-center steering wheel.


Am I leaving out anything? The lift has both track bars and all 8 arms, along with OME shocks and lots of other goodies. Should I do any of the lift with the TC skid off or can I button it back up after the SYE adventure?

Does my order for the wheels sound decent, with the new, extended brake lines from the lift kit coming at this time? Or should I wait on the lines until where the lift instructions say to remove and replace them?

Are there any points where I need to button the whole thing back up and test drive it before the next step, or can I do all this in one straight shot over about a week?

This is so much stuff that I am getting overwhelmed at thinking of how long it will take me. I have never done this much to a vehicle in one shot...

EDIT: The nice fellow in the YJ section suggested to me the method of working on the crush sleeve in the D44. I though there was no crush sleeve, just the bearing and cap. Will I have to set a 10 inch pound preload or is this a fiction?

If so, it is the only thing I feel unqualified to do. Should I save that for a shop or just jump in and learn? Is it difficult? I *do* have an inch pound torque wrench if needed.

Further, he suggested to me to save the driveshaft order for after the lift is in. I ordered it as a kit from 4X4GroupBuy - SYE and shaft in one kit. I sent them some measurements based on a form from TW and they ordered it for me.

Was this a mistake???


2003 Shale Green Metallic TJ Sport
2013 Black JK Sport S

A yellow bird with a yellow bill landed on my windowsill. You know the rest...
Holton345 is offline   Quote
Old 06-21-2014, 09:03 AM   #2
Join Date: Oct 2011
Posts: 3,960
Originally Posted by Holton345 View Post

EDIT: The nice fellow in the YJ section suggested to me the method of working on the crush sleeve in the D44. I though there was no crush sleeve, just the bearing and cap. Will I have to set a 10 inch pound preload or is this a fiction?
The FSM is in the non-fiction category. It's a lot better source of information than nice folks who think all axles are the same.
tangofox007 is offline   Quote

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