TerryMason's 2005 Jeep TJ Build

[TerryMason]

I decided to ditch the original skid plates - they hang alittle low for my taste. After some research I ended up with the Extra Clearance Skid plate from Undercover Fabrication. I bought the Extra Clearance which requires a body lift (it has a two inch drop to it), as well as their engine skid. The install was pretty easy, and the only holes that need to be drilled are to connect the engine skid to the transmission skid (you are actually drilling 4 holes in the transmission skid).

Here's the kit I bought:
Under Cover Fabworks, LLC - UCF Deep-Cover Skid Plate System















I haven't taken it on the rocks yet, but the system fits nicely (It really hugs my automatic transmission pan).

[TerryMason]

At some point (I can't really remember when), I installed a transmission cooler in order to keep my automatic transmission nice and cool.

You can see the full install here:
http://www.jeepz.com/forum/engine/40...r-install.html (Transmission cooler install)

[Y2KTJ]

Touche' Sir, I never even thought of that. I do run 456's now, so he is actually giving me a pretty good deal re gear, locker install and ready to bolt in. soooo I may end up with that. I honestly never even thought about the disc brake set up allowing for that. Thats why I love the forums. Thanks and I will keep you posted.

[TerryMason]

Here's some before and after on the Undercover Fab skid plates.

Before - 13.5 inches of clearance


After - 15.5 inches of clearance.


You can tell it's a bit smoother underneath as well
Before:


After:

[Sapfan]

Just curious if you know your rear brake calipers are supposed to be mounted on the rear of the axle? I think you have the backing plates on the wrong side

[JPNinPA]

Bump stops?

[Sapfan]

If you look at the picture of when you brought the axle home, the brake calipers are in the correct location on the backside of the axle. In the picture of when its done the brake calipers are on the front side of the axle. You need to pull the calipers, and backing plates and move the right side to the left side and vise versa.

[TerryMason]

Just curious if you know your rear brake calipers are supposed to be mounted on the rear of the axle? I think you have the backing plates on the wrong side

You're totally right. I never even noticed it. I guess I have some work to do tonight. It may make my e-brake cables reach a bit farther as well. Thanks for the heads up.

Bump stops?

I do have bump stops installed (the stock cup with the bump stops from my 2 inch kit). I haven't taken the time to flex things out and see if they are spaced correctly. You can see what I mean here:



Is that what you meant, or something else?

[JPNinPA]

You're totally right. I never even noticed it. I guess I have some work to do tonight. It may make my e-brake cables reach a bit farther as well. Thanks for the heads up.

I do have bump stops installed (the stock cup with the bump stops from my 2 inch kit). I haven't taken the time to flex things out and see if they are spaced correctly. You can see what I mean here:

<img src="http://www.jeepz.com/forum/attachment.php?attachmentid=16299"/>

Is that what you meant, or something else?

Might read this about out boarding shocks.
http://www.jeepforum.com/forum/f9/ou...-when-1464875/
http://www.jeepforum.com/forum/f9/re...te-up-1297324/

For the bump stops. I didn't see it in the write up, nor an image post springs to see the delta of shock travel to bump space. Plus it is important for someone following the thread for their modifications.

[TerryMason]

I think you have the backing plates on the wrong side

I spent some time this weekend and straightened out the brakes. I ended up having to pull the axles out, which meant draining the diff and pulling the c-clips... I didn't think much about it before starting, but laying on the cold ground covered in stinky gear oil is no way to spend a Saturday night



Thanks again for pointing out this problem. I really didn't notice, and now I think I've picked up some needed slack in my parking brake cable.

Might read this about out boarding shocks.

I had never heard about this before, and did some reading. It looks awesome, but a pretty good sized project at the same time. I'm going to have to do something, because after installing my belly up skid plate (and then rolling the pinion angle up) the shocks are contacting my coil bucket.

[TerryMason]

I got this compressor from a guy at work, and decided to hookup some On-board air for the old Jeep. I sprung for a Viair 2.5 gallon tank (model 91028) and some standard compressor hose and rigged everything up. I've got a switch mounted with my other stock switches to turn it on and off, a pressure regulator to keep it from going over pressure, and a tank that I hook a hose to when needed.

[Utah_jeepster]

Just a few pointers Terry, run your air in-let line through your fire-wall too much dust, oil, and possibly water. and get rid of that cheesy "manual" tank drain. Go to Graingers and get a 12v air valve and hook it up to a switch...lazy mans tank draining.




Hey just noticed something...looking through your build thread...your mounting everything like I did....quit copying me!

[TerryMason]

As I mentioned, the rear axle / coil bucket was hitting my shocks as the axle flexed out. I bought some shock extenders, but ended up not using them.

I decided instead to use some new shocks that mounted upside down (can up). It seems to have worked out nicely.

These are the Rough Country 22004 and 22005 shocks. They ride fine, and look pretty slick. The best part is that now there's plenty of room for my axles to flex out.

[MY95YJ]

Very nice TJ!

Sent from my SCH-R830 using Tapatalk 2

[SpikeHorn]

Really cool TJ.

[TerryMason]

I thought it may be time to tally up everything that I've done to the Jeep so far. Here are some photos of my Jeep now:










And here's the rundown:
2005 Jeep Wrangler SE (4.0L, Automatic)
33" BFG KM2s
Rough Country 2.5" lift springs
1.25" JKS body lift
Savvy / Currie aluminimum adjustable control arms
Ford 8.8 rear axle (with rebult factory LSD)
SYE with cut down Cherokee CV driveshaft
Aussie locker in the front axle
Undercover Fab low profile skid plates
Viair onboard air with 1.5 gallon tank
Trail Gear rock sliders
Ground Pounder Fab front bumper
Exogate spare tire carrier


There are plenty of other little odds and ends, but these are the big items.

[Ken@WD]

What a great looking TJ Terry, can't wait to see your nice set of GraBars installed!

[TerryMason]

After a recent offroad trip I was getting a loud and annoying squeak from the front axle whenever I was in 4x4. It looks like the axle u-joints are too blame, so they were swapped out today.

Old crusty joints:



Shiny new Spicer Joints (from amazon) installed:



I did a full writeup here:
http://www.jeepz.com/forum/drivetrai...tml#post323804 (Wrangler Front axle u-joint replacement)

[flatie46]

I had to go back to the first pic and compair photos. You've really come a long way man. Also some good choices along the way. I know you said in the begining it was a daily driver. I'd say it's very capable trail Jeep but does not infringe on DD service. Congrads man you've done well! Here's to a well built JEEP!

[TerryMason]

Some squeaking from the front end resulted in a rebuild of my front driveshaft. Not a minute too soon!








Here's the full writeup
http://www.jeepz.com/forum/drivetrai...n-rebuild.html (Jeep front driveshaft (CV / dual cardan) rebuild)