New WJ build

[Ted_Z]

So I picked up a 2002 limited. I was originally set on getting a Laredo, but all the bells and whistles on the interior actually work on this one including the dual climate control and heated seats. Also the front suspension had recently been revamped with all new tie rod ends and control arms/bushings. Seller claimed it had a rebuilt engine and low mileage trans. Has up country springs, all skids and tow hooks and tow package. My kids love it, especially the sun roof for some reason.

Done to date:

• Infinity amp by-pass and aftermarket head unit
• Refinished headlights
• JK take-off wheels
• Fixed power seat base
• Removed pealing chrome badges
• New lift-glass shocks

Current list of to-do's basic stuff:

• New spring isolators
• New front sway bar bushing
• New rear lower control arms/bushings
• New rear a-arm, bushings, ball joint

2" lift related stuff to install:

• 2" BDS springs
• JKS sway bar disconects
• JKS adjustable track bar
• JK Rubicon take off shocks

I'm looking for some Overland rock rails if anyone has a lead for some in Denver.

How it looked the day I brought it home:

[Ted_Z]

Pic's of the new wheels and badges delete. Also put on some cross rails.

[jsteves]

Already looks better!

[killallblue]

looking good

[Ted_Z]

Had a chance to play in the garage over the weekend.

The JK rubicon take-off shocks compared to the OEM ones. As you can see they are about 2-3" longer than stock. Pressing out the sleeves and bar pins was a little tricky using socket and a bench vice, but definitely doable.



Comparing rear factory springs to +2" ones (didn't get a pic of fronts side-by-side):


Out with the old, in with the new. Changed rear control arms and all 8 spring isolators. Front had basically new arms/bushings.



Ran into a bit of rust on the rear lower spring mounts put it cleaned up ok.



Front lower spring mounts where toast. I wasn't able to finish the install as a result. Ordered the spring mount repair parts from Iron rock. Also ordered the lower spring retainers while I was at it.

[Ted_Z]

Even only at +2" lift the bushings on the rear A-arm are at a nasty angle. I can see these wearing out quickly. Current plan is to install some flex joints in place of the bushings.

[dp96zj]

Might as well just go long-arms!

[Ted_Z]

Might as well just go long-arms!

All in due time

[Ted_Z]

I want to donkey punch whoever came up with this design. I don't understand why you need a rubber isolator on the bottom of the spring. Just a place for corrosion to accumulate.



Welded up the IRO spring repair parts. They required a bit of trimming to clear the lower sway bar mounts. Also made some upper spring mount extensions/ spring retainers out of some scrap tube a a couple fender washers. These bolt to the upper spring mounts.




Got it all buttoned up. JKS diso's are in. Adjustable track bar in (with new bushings). JK Rubicon shocks are in and fit perfect.

[dp96zj]

I dunno why, but the pictures in your last post aren't working for me?

Oh, and it looks like we both stumbled onto similar Jeeps, mine's an '02 Limited as well. I'll be watching your thread often!

EDIT: Deleted my picture to keep from hijacking your thread!

[Ted_Z]

After picture. for those who care hub to fender dimensions are: Front - 20 1/4" Rear 21"

[Ted_Z]

Fixed fix the pictures...

[Stealth Crawler ZJ]

I dunno why, but the pictures in your last post aren't working for me?

Oh, and it looks like we both stumbled onto similar Jeeps, mine's an '02 Limited as well. I'll be watching your thread often!

Nice rig man!...😎
Could look just like this eh?

[Ted_Z]

So I think finding Overland rock rails is going to be damn near impossible. I did however pick up a pair of JK Rubicon rock rails for $50. They've seen some light use but still perfectly serviceable.

I cut them down to 70 1/4" long (removed material from the rear side of the rail). I'm still sorting out exactly how I want to mount them.

I didn't want to use a traditional aftermarket rock rail as they hang down about 2". Once these are installed I should only give up 1/2".

The slight curve of the JK rail matches the WJ body almost perfect.

[JohnBoulderCO]

Looking great!

[JohnBoulderCO]

Windshield wash bottle relocation - needs to be on your To-Do-List before putting on the larger tires

[Ted_Z]

Good advice! I've seen 2 types of swaps, one puts the bottle next to the master cylinder, the other uses a ZJ reservoir but requires an aftermarket air intake/filter.

I have a 2002 so the charcoal canister is in the back so at least that is not in the way of the first option. I'd rather do the ZJ bottle swap since that looks like it would have more capacity. But Then we're talking about doing the intake too.

On a related note, will the charcoal canister under the rear bumper be in the way eventually?

[Ted_Z]

After a bit more searching, it looks like i can do the ZJ washer bottle swap without removing the factory air box. Looks like that is next on my list.

[Mtn WJ]

Looks good,

I put a rectangle shaped water bottle on my WJ in place of the factory washer bottle. I got it at Walmart. Very simple and just drilled holes to swap in the pumps and sensor. It just squeezed between the factory air box and the fender wall. I have a CAI but it is the type that uses the original box and air inlet from grille to give me a true cold air. So the water bottle concept worked in both applications for me. Its about 2 quarts so smaller than factory, but still decent sized.

For my son's WJ I looked for Overland Rails and when I found them, they didnt seem any better than the original Mopar rails I had on my WJ when new. So we got a set of rock rails from a local company and I re-welded the mounts to move it up in a way similar to the Rocky Road rails I have on my WJ. This seems essential on 2-3 inch lifted WJs. I like your modification to the JK rails. You might want to beef up the mount surface under the Jeep.

[Ted_Z]

I got a bunch of small things done on the WJ

Oil change (mobil 1) and air filter
Changed differential lube front/rear
Changed t-case fluid with the Mopar special 247 fluild
Coolant flush (once with the flush stuff and once with water) then added the G-05 coolant
ZJ washer bottle swap and fixed the sprayers (clogged check valve/y-fitting)
New spark plugs
New PCV valve
New fuel filter/regulator
Replaced front sway bar bushings (body side)


I also found a set of Overland rails that are in reasonable shape. I can't decide if I should refurb them or continue with the JK rail project.

[Ted_Z]

Next up swap the steering box (leaking) and new motor mounts.

[fischerry]

Noce looking rig

[ELLLLLIOTTTTT]

I need some updates to motivate my newly founded WJ bug.

[Ted_Z]

Wish I had more to tell. I plan on getting under the jeep to do the steering box this Friday (day off). I might add new rear sway bar links to the to-do list ad I'm getting sick of the clunking sounds (wasn't the rear upper shock bolts).

I'll be sure to post an unreasonable amount of pictures of the steering box swap!

[ELLLLLIOTTTTT]

I too need to replace the steering box. The pump has also been whining for the last year but isn't getting any worse.