I think we'll name her Sparrow (buildup)

[JambaJeep]

So I am a bit behind as far as build up pics go but it's better late than never. So here we go.

In the summer of 2016 I purchased a 1999 Jeep Wrangler for $3,800 and drove it home all the way home from the Dalles.. With a blown up rear end, severely neglected exhaust leak and cracked header, the transfer case wouldn't shift into anything besides 2-hi, and the clutch pedal was feeling a little depressed (punk intended). This thing drove down the highway like a washing machine loaded with cinder blocks, I was second guessing myself all the way home. Also just about every u-joints was shot.

The annual 4th of July Liberty trip was coming up in about 2 weeks. I pulled the transfer case out to figure out why it wouldn't shift and installed a new chain and advanced adapters SYE kit with a Rubicon Express double Carden driveshaft, and a Novak cable shifter kit. The skid plate was severely bent and someone generously gave me their stock one after they got a tummy tuck kit. So the transfer case was fixed, now onto the transmission.

I pulled the transmission and found the clutch fork was snapped in 2 pieces. I got that replaced, resurfaced the flywheel and installed a new clutch and pressure plate. Got that all back on and moved up to the exhaust manifold, I got an OEM upgrade exhaust manifold with the accordian expansions in it and a thrush muffler. Good as new, or better.

Next was the dreaded rear end, I pulled the cover and drained the fluid, holy stardust was there a lot of glitter in there. Problem was the completely destroyed spider gears, so Rockauto and overnight shipping to the rescue. Tim helped press the new carrier bearing on and I put new spider gears in. Good as new.. Or so I thought.

The vibration was significantly better but something was still not right. There was an odd rumble upon deceleration. Seems someone overlooked correcting pinion angle with the SYE install..

TJDave rescued me on that one and let me borrow some worn out RE adjustable control arms, ok so now we're good.

Lastly was tearing all that nasty carpet out, and installing the CB radio, I opted for a Cobra 75 handheld unit.

Now I could get into the suspension and give this little jeep a little more height. I put late model crown victory rear springs in the back and V8 ZJ coils up front, I got about 3" of lift out of the junkyard boost. I didnt want to skimp on shocks so I got Rancho 9000's all the way around.

[JambaJeep]

Just before the liberty trip I fabricated a shorty front bumper with winch plate and rock bars. I have pics somewhere. I cut a piece of 2x6 square tube into 2 L shape pieces and notched accordingly.

I don't remember exactly why I did it but I ordered a custom front driveshaft from Adam's Driveshaft.

I mounted a hi-lift with some fence post clamps and wing nuts, works great.

[JambaJeep]

Fast forward about 1 year, a few wheeling trips, a baby, new house, and the next liberty trip we arrive at me grenading my rear driveshaft when I got a little too much hop and my jumbo bumps tops didn't work.

I used the minor break as an opportunity to build a bulletproof set of axles for 35" tires.

The front I opted for a full retard build, High Pinion dana 30 from a late model XJ. I fully trussed and gusseted the axle, ordered chromoly axle shaft, found a used Eaton E-locker on CL, ordered a ZJ tie rod, centric rotors, black magic pads, new unit bearings and calipers. I was reluctant, but convinced myself the undertake the gear setup all by myself. It was a valuable lesson and I will never be afraid to set up gears ever again. I went with 4.88 gears since I don't plan to cruise the freeway much in the jeep.

The rear I opted for something with disc brakes, 5 on 4.5 lugs and cheap. I scored a 2000 Ford Explorer 8.8 with disc brakes for $150. Trussed and gusseted, welded the axles tubes to the center section (prone to spinning) threw in 4.88's and a matching Eaton E locker. I am glad I spent the time to teach myself how to properly set up gears and am thankful for Roman and Lurch for letting me get some final opinions on my gear patterns.

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[JambaJeep]

Got the new dirty 30 installed.
2000 Cherokee High Pinion Dana 30

2000 wrangler calipers, unit bearings, centric premium rotors, (gets rid of the weird split in 99 of rotors and until bearings)

Black Magic break pads

Iron Rock Off road D30 truss and knuckle gussets

USA Standard Gear 4.88 gears

USA Standard Gear chromoly axle shafts

ZJ Tie Rod (beefy upgrade to stock tj tie rod)

Eaton E-Locker

Core 4x4 Adjustable control arms

Added a 1" daystar budget boost to level everything out

Riddler diff cover

Early Chevy front brake lines (budget extended brake lines for yj and tj's from Napa for $7 each, straight bolt on 4-5" longer)

Probably forgot something, and I don't know why all my pics post rotated 90°

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[Roman]

Not very photogenic, looks way better in person

[JambaJeep]

Rears in! 2000 ford exploder 8.8 (31 spline) disc brakes WITH FACTORY E-BRAKE, Eaton e-locker, 4.88's, trussed, welded tubes, yadda yadda

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[JambaJeep]

This weekends project: on board air!

https://wranglertjforum.com/threads/on-board-air-conversion-of-stock-jeep-wrangler-tj-a-c-system.3672

[Roman]

Talk about over complicated

[bobracing]

If using the stock compressor, plug the transfer port and use a heavy grease.

http://www.grungle.com/endlessair.html

[Zapp84]

Any update on this build?

[Gregandlina]

I can say the on board air works great!