Got some work done this weekend FINALLY

I got my axle re centered by installing the RE Track Bar.

Also got the 5-1/4 marine speakers installed in the kick panels which turned out pretty sweet.




Now I can take the doors off and still have sound. Also since there water proof I can still spray down the inside of the jeep and not have to worry about messin them up.

 

Well it's been about a year now since I opened this thread so I thought I'd do an update to show the progress that's been made.

Then:


Now:


As the jeep sits now:

Suspension and Tires: 4.5" lift w/ 33's
3" Rusty coils w/ 2.25" spacer
S-10 Bastard Pack w/ 1.5" Rusty's lift shackles
Rusty's LCA's for 4.5" lift
RE Track bar w/ Frame Brace
RC Disco's
RC 9000 Shocks
1" TC Drop
YJ brake lines
Trimmed Fenders
33x12.50x15 Pro Comp X-treme M/T's on 15X8 3.73bs rims

Performance:
Drop in K&N Filter
1" TB Spacer
Custom 2.5" exhuast with Flowmaster 44 and high flow cat

Protection:
Engine, T-case, and gas tank skids
Homemade Front Bumper with 8000lb Champion Winch
Homemade Rock Sliders

Axles:
HP D30 x297 u-joints
D44 w/ Disc Brakes

Extras
Wilderness roof rack
Bed-lined Interior
Durango Steering Box conversion
Inner Steering Box Brace
Removable front doors
Marine Speakers


Future:
Install 4.56 gears and lockrights
SYE
Long Arms
Install RE 5.5" Coils
Electric fan conversion with a Turras fan.

 

Nice Jeep

 

Can i request some pictures of that roof rack? I'm looking into getting one. close up pictures?

 

Cough* Cough* Cough* ....

Man, I'm brushing some dust off this thread. Been a while since I last did any really updates on the Jeep. However, I've been saving up for a while now and it's time to make some big changes over the next three months:

IRO OTK Steering
IRO 4.5" lift springs to get rid of the spacers
Switch for 1st gear lock and Torque converter lock out
Swaping over to a 96 Brake Booster and Master Cylinder
Installing Ford Tarrus Fan
Dodge Neon Injectors
Sub Woofer Install
4.56 Gears and install the lockrights i've had sittin round for a year now.

Who knows what else I'll throw in while I'm at it, but here's a pic from last weekend though at URE for starters:

 

I would appreciate it if you go ahead and document all of that stuff well, because I'll be looking to do some of that in the near future too. M'kay thanks

 

Great looking trail rig/DD....I love the roof rack..

 

You jeep looks great man.

 

Thanks guys for the comments, I'll do my best to keep this stuff documented. Well today the parts came in for the brake upgrade:


96 Master Cylinder with Brake Booster


96 Brake Booster


ZJ Proportioning Valve

Sorry for the bad photos, camera phone...

 

Well got some work done on the Jeep moving today, little ironic since I started with making it stop. Took out the old setup:



94 ABS booster & Master Cylinder w/ XJ ABS proportioning valve.

For this one:



96 Non ABS booster & Master Cylinder w/ ZJ proportioning valve.

Install went pretty clean with a few hick ups here and there. Remove of everything is pretty straight forward. First off do not take the top off the master cylinder, little fact of gravity the brake fluid will not flow out like a stream this way. Now I can go into the real details like taking out the air box. Then unhook the lines from the master cylinder to proportioning valve and run them into a small bucket to catch the drip off. From there the rest off the proportioning valve can be removed. The booster is also just a straight simple un bolt it procedure.

The hard part comes in with putting in the new booster / master cylinder. With the 94 booster ABS style it's its own unit. Jeep ran it one year for a reason. Reading some only thread it was said to be the double style booster like the 96 however, I've had both and it's not. The 94 while it is a double booster is mid-way between the size of a single booster and a 96 double booster. I can also say why Jeep probably had it for one year. This is the second time I've blown it out along with the master cylinder after replacing it last year. Due to some changes since then like my D44 rear with disc brakes and removing the ABS a non - ABS 96 Booster was in order.

The 96 Booster has a longer rod on it which many people say you should solve with a spacer plate. This is true I guess, however I prefer actually adjusting the push rod inside the booster. The first time I didn't get it quite right and had to pull over on the side of the during the test drive to pull the master cylinder back off readjust the length. It's very easy to do, more on that later.

To initial check the rod length bolt the brake booster to the firewall. Then mock up the master cylinder by pushing it all the way back against the booster without applying much force. At the point where the pressure is applied is the point where the rod is pushing on the master cylinder. If it's pushing before hitting the back of the booster adjust the rod back by taking a 7mm socket on the end bolt of the round while holding a pair of pliers on the part it screws into. Then just tighten down as needed. Once you think you got it right bolt the master up.

From there you can do like me and do the proportioning valve upgrade if your like me and have switched to disc brakes. This requires flaring all the ZJ line fittings on your brake lines as needed so that it will bolt up. This is the most skill full and pain in the rear part of the job. Note some of them will not need to be change depending on your application so compare the to proportioning valves out side the jeep as to what needs to be changed.

After that its just the simple matter of bolting everything up and bleeding the brakes very well. If your like me this involved a pair of channel locks to remove 2 of the bleed screws. So I cracked them all open and gravity bleed the system while I went to the parts store to get new bleeder screws. Once back I bleed them as normal.

Now on to the test drive where I had to pull over. I noticed the jeep was taking more strain to get up to speed, I since this was due to a braking issue since I just replaced them. Sure enough I pull over and see some smoke coming out the wheel wells. Good news after a look over everything looked out as they only got warm enough just to take some miles off the pads. Now how to fix it on the side of the road. Obviously removing a brake system you put together on the side of the road is not a option. So take a 13mm wrench and unbolt the master cylinder. I was able to pull the master off the booster enough to get the socket on the rod in the booster to screw it down far enough to clear better. Bolted the master back up to the booster and drove it all day no issues.

So in conclusion i love it!! I changed this setup out last year for the original so I can say I can compare new to new. The stopping power I have with the jeep in awesome with the Booster, Master, Proportioning, combo along with the 4 wheel disc brakes on 33's. I can stop better than I could when I got the jeep stock on 28's with ABS. Best thing was the upgrade was "free" cause autozone was nice enough to transfer my life time warranty from my 94 parts over to clamming them on the 96 parts.

Now not to take away the thunder from this upgrade but I figure if you took the time to read this you might as well now what else I got for absolutely free. A 99+ Intake Mainfold from my buddy along with the power steering pump and all the goodies. More on that later!

 

Thats awesome! I've been thinking about the dual diaphragm booster.

 

Well been workin on wiring up the new system in the jeep today. Project includes wiring up the 200w Sub with a 6ga wiring kit along with cutting into the back hatch to install the 6x9 speakers. Will be throwing up some pictures later.

 

The time has come! Parts finally arrived for the steering on the Jeep IRO's OTK Steering. Also all the parts for the regear should be here next week!

Plans for next week included:

Installing OTK Steering
Welding the Track Bar Bracket to the Frame
Installing the new Gears and locker

Hopefully it all goes smooth

 

The work has begun!


Old Steering


IRO OTK Steering + plus kitten


Old Steering Gone


OTK Driver Side


OTK Passenger Side


OTK Fully Mocked up

2morrow I plan on tightening up the steering and getting the angles right. Then I'm throwin on the new 4.5" coils.

 

Cough* Cough* ... Dang this thread is dusty. On the lighter side I finally finished throwing in my 4.56 Gears, Front Lock Right, and Rear Detroit today.