Project "Fix and Build"
 

Greetings,
I wanted to start one of these build threads for two reasons.
1) I have a 2000 xj 4.0, 105K, I have had it for about 2.5 years now, I use it as a daily driver. I have a Thule rack on it, so I carry bunch of sports equipment with it, and I pull my sleds in the winter. Recently I went to get it inspected and low and behold I needed a bunch of new parts.
ball joints
front axle shaft U-joints
steering stabilizer
new tires
sway bar links
new tools

so I did what any normal hot blooded male would do... Upgrade!

2) I started reading CF not too long ago and I love to follow the build threads, from stock to always improving. Everyone seems to help one another in this forum. It's a great feeling to build and have something to show for your hard work and I would like to be a part of it.

Anyways, so I ordered and installed a bunch of replacement parts
spicer u joints
skyjacker stabilizer
spicer ball joints
Attachment 22617Attachment 22618
The stabilizer upper tapered bolt was rusted and was PAIN to get out. used days and days of pb, pickle forks, and just plain hammering, finally got it out with my ball joint remover kit....


I had already bought some tires off a friend that were from his stock LJ. $50/ tire for GY wrangler snow/ rain A/T 30X9.5 tires with about 90% life on them. Not the biggest tires, but for now....since my idea for the XJ is still daily driving, but for future use will be my summer offroading/ winter vehicle, they'll do fine for now.
Attachment 22619

and the stock rims had some rust on the edges, so sanded down, primed and painted a dark graphite black(just the primed is shown...
Attachment 22620Attachment 22621

AND finally I ordered my Rusty's 3" lift AAL kit, got it in yesterday! This is after I had already ordered a RE 2" budget lift. It's been on back order since june 15th because they didn't have the front spacers....
Attachment 22622

I'm trying locate some new sway bar links, I ordered new stock ones...cause I'm an idiot.. and now have to find new ones, hopefully I can find some used or just some brackets, as well get some new bottom bolts with the eyelet and cotter pin disco mod

The only pic I could find of the jeep was this one after I towed out a sailboat out of Lake George, NY :DAttachment 22623

great job! I look forward to reading about your progress! :icon_cheesygrin:

so once your RE 2" budget boost comes in your gonna add that onto there as well right?? then your sittin at 5"..lol jeep looks nice and sounds like its gonna be pretty sweet when you are done. RC makes a sway bar QD that is i think like $49

I totally would if I had bigger tires, and the time to install the sye, new control arms, etc! But I haven't driven the jeep in a month and I seriously miss it. I'm driving a 98 corolla right now :wallbash:
but nah I cancelled that order, I mean a month is a little ridiculous for spacers.

Also just ordered some pro comp fog lights and going to try to use my old stock roof rack for a light bar.

we need more pics!!!!!!

slow start
 

I'll get them out soon. Having a really tough time getting started tonight. Guess I'm pulling an all nighter to get this lift done, jacked up on coffee, beef and broccoli, and beer... anyone else??

Broke my lower shock bolts! help!
 

Attachment 22841
any ideas???

there are alot of write ups on here about that particular problem...that sucks man i am sorry that happened.

Yeah I found them thanks, Kinda freaked out when I realized it was a welded sleeve and head and not a bushing...Just going to have to wait and get a tungsten carbide drill bit and drill not only the head of the welded screw, but the easy-out that broke in there as well......ahem..:hang:

broke rear lower shock stud, misaligned LCA
 

Over the weekend I put in some good hours getting the lift installed. Of course a few hang ups got in the way. So waiting on a couple parts and need to figure out somethings as well. I'll have pics up soon

1) broke the lower shock mount, it happens I know, but I wasn't convinced of just drilling and putting in a grade 8 bolt in there, and I don't have a welder. I got a suggestion about sleeved sholder bolts and I found this bolt
http://www.speedwaymotors.com/Shock-...tuds,5485.html

The shoulder next to the sleeve has more surface area against the welded mount, in turn the force of the weight of the truck causes a moment on the stud which is dispersed over that extra area, so there is a less chance of any sagging on the stud. The other option of course was to grind off the old mounts, buy new mounts and get more clearance, but since the bolt is $3, I'll wait on this mod til later.

2) my driver side of my front axle seems to be moved forward about an inch, making it difficult to push the LCA into its mounting hole. I tried propping my jack on an angled piece of rubber but I still couldnt get close enough to put the bolt in. any suggestions?

Other than that, my stupid leaf U bolts aren't really the right size, so I have to compress them to fit in those square brackets. PITA!

Next after the lift is - align; drain my front diff/ new gasket is in; new pro comp fogs on; bondo a couple small rust spots on my window gasket that I grinded off. and should be good for a few more days :)

Need some suggestions on mounting the lower fron control arm, Hopefully I am missing something very simple? it just seems that the axle is moved forward an inch. (see previous post)

Sorry no pics up yet, been busy the past couple days. But tonight I'm heading back in the garage to finish up some things.
thanks!

so I havent spent the time fooling around with photobucket so I can only attach 5 pics at once...

attached are some pics that I took since the weekend.

Figured out the LCA issue, had to use two jacks, one to move the axle back, the other to raise to get that friggin bolt in. here's the finished front, new ujoints, ball joints, 3"coils and springs, finished minus the bump stop just chillin in the coil
Attachment 23161

broke the lower shock mount stud as mentioned before,
Attachment 23162

heres my buddy trying to use an easy out on it
Attachment 23163

....and here's the easy out broken off in the stud.....
Attachment 23166

Here's another nice little tid bit I found out when I brought in my jeep to get it inspected last month
Attachment 23164
my passenger side LCA bolts was sheared right off, no idea it did this and I was jumping train tracks during the time.....awesome

Just think it jumps train tracks with the broken bolt, it should be fine offroading if you break bolts... Good thing you found it now, before it did let go whlie you were driving down the road...

I tried getting the brake line off the E bracket
Attachment 23173
But it was pretty rusted and was only turning the metal tube. So I 'temporarily' put the Z bracket that came with my rusty's kit on top of the axle, I know it'll catch if I leave it there too long, so I'm going to order a new brake line
Attachment 23176

I got lucky and didn't break either of the nuts on top of the leafs, I did soak them in PB for awhile while brushing the old rust off and resoaking.
Attachment 23177

Also, primed and painted the stock leafs, look way better on the truck
Attachment 23175
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