98 TJ Build from stock to finish and the futile pursuit of finality

[stan98TJ]

Ok, let's bring this up to date.
Last week the Jeep ran. Finally got the axles back in, bolted it all up, ran into a small snag with a control arm bolt(s) size. Basically needed longer ones cause Dan beefed up the mounts and bolt holes since they had wallowed out.

So got everything back in and took it for a ride to a buddy's shop to take a look at some leaks. When i had picked up my axles from Dan, we had a miscommunication between us and I understood that the front axle was empty and unsealed and needed RTV and gear oil and I understood that the rear was filled and sealed. 3 miles later I found out the rear was just sealed... Loud metallic crunch, followed by a series of bangs, wheels locked up jeep skidded to side of the road. Driver behind me sh*t himself and all that was left for me to do was hop out and yell "Tadaaa!"

I placed a call to Dan and the jeep was flatbedded to his place. My buddy Sean (Rockthe40oz) came up from LI and we had the axle out in 40min. Dan then began the process of taking the diff apart with the aid of a mirror as it was rotated inwards. Yeah, A LOT of patience. Parts were ordered and Dan didn't ask any questions, no discussions, he waived the labor, hooked it up On the cost of parts and had it set back up 48hrs after the parts got to him. Axle went in wed night.

If anyone needs parts or work done, give Dan McPhearson a shout. Look him up on Facebook by Name or look up DMR Transmission on Facebook. He also posts on here under the name ct67_72
I pretty much got most of my parts for this project from him and he helped a lot on the prices.

 

[clean4drxj]

Dan's one of my friends.. Not only is he good with diffs, his prices are unbeatable, and he's a very understanding/good all around guy. I would recommend him to anyone.

 

[PaulW]

Dan's one of my friends.. Not only is he good with diffs, his prices are unbeatable, and he's a very understanding/good all around guy. I would recommend him to anyone.

Dan's a duche :razz:, but he does great work.  I would hire him to do work on my shitbox, if 1. I had a shitbox worthy of working on, and 2. if I could afford to work on said shitbox.

 

[stan98TJ]

So a little update about the build.
Turns out I had forgotten to mount the little transmission plate inside the skid plate. UCF has you take the old mount off your old skid and bolt it to theirs. I was rocking it without it. Luckily the transmission was tucked up there tight and didn't move around too much. SO, since I still had my old skid, I took down the new tummy tuck skid, bolted on the mount and bolted it back up. Only to find that my linkage is all pressed against the tub now, preventing me from shifting into 4wd. It actually sounded like it was in the middle of 2wd and 4wd. So, the new skid came down and the old one went back on. The only solution to have it fit is to run a cable shift. Since I plan on swapping in an Atlas case this spring/summer when I come home from sea, I will wait til then. The Atlas comes with a cable shift so I'd rather do that then buy a novak as a temporary solution.

 

[JohnyPro]

Novak shift cable. Done.

 

[stan98TJ]

Novak shift cable. Done.

I was going to, but the Atlas case comes with one.  so I'll just wait til I swap the atlas in this spring/summer.

 

[PaulW]

Novak shift cable. Done.

I was going to, but the Atlas case comes with one.  so I'll just wait til I swap the atlas in this spring/summer.

Are you doing an aw4?  I'm running scrap tomorrow it's going in the trash if you don't want it.

 

[stan98TJ]

Novak shift cable. Done.

I was going to, but the Atlas case comes with one.  so I'll just wait til I swap the atlas in this spring/summer.

Are you doing an aw4?  I'm running scrap tomorrow it's going in the trash if you don't want it.

I appreciate the offer, Paul. I'm going to wait til HPA gets their aw4/TDI swap kit out (should be later this year) before I settle on finding one. These guys keep coming out with new stuff all the time, they may even decide to go with the TJ 4spd.
This spring/summer, however I'll more than likely do an Atlas 4spd

 

[PaulW]

Cool.  Can't wait to see the finished product.

 

[massxj]

I want to see this when the swap is done

 

[stan98TJ]

I want to see this when the swap is done

Swap is going to have to happen. Got some bad news recently. The "trusty" 4banger is on its way out- unless I rebuild it. Barely 45k on the clock, had a cyl leak down test done. Have about 43% loss in cyl 2 and 3. This is my 2nd engine. The first blew up 4 days after purchase at 86k. For years I've been chasing down leaks as it leaked from every possible seal. This was a rebuilt motor I purchased "new" from S&S in Washington in 2008. At this point I have had every single major part of the drivetrain blow up on me: engine, transmission and transfer case.
Not going to waste my time with another 4cyl. Diesel is a def go.

 

[WickedWrangler15]

This thread was missing something...

...much better.

RM

 

[stan98TJ]

This thread was missing something...

...much better.

RM

AHHAHAH!
thanks.

 

[MasterDrazhar]

...Only to find that my linkage is all pressed against the tub now, preventing me from shifting into 4wd. It actually sounded like it was in the middle of 2wd and 4wd. So, the new skid came down and the old one went back on. The only solution to have it fit is to run a cable shift...

Just pound out a relief pocket in the tunnel for the linkage to move in.  If you read up on a majority of the tummy tucks that's what you need to do for linkage clearance.  Don't need much.

 

[stan98TJ]

...Only to find that my linkage is all pressed against the tub now, preventing me from shifting into 4wd. It actually sounded like it was in the middle of 2wd and 4wd. So, the new skid came down and the old one went back on. The only solution to have it fit is to run a cable shift...

Just pound out a relief pocket in the tunnel for the linkage to move in.  If you read up on a majority of the tummy tucks that's what you need to do for linkage clearance.  Don't need much.

I feel like it's a significant amount to pound out. Without the mount, it was close to begin with, maybe even resting against the tub. Then when I put in the mount, it was enough to push the lever so that I lost 4lo completely and was basically in between 2hi and 4hi. I feel like the tub may get massaged for the Atlas so i'll do it then.
Not wheeling for the rest of the winter, looking to go back to work soon so I'll be overseas and the Jeep will sit for 4 months. The stock t-case allows me to run 4wd for the snow we're getting. This summer when I swap in the atlas, i'll pound out what I need and fit the flat skid back on.