92 yj rebuild

[redneck23ms]

i bought this yj in april of 2012. it had 2.5" suspension lift, 1" body lift, sye, hardtop and hard doors and pretty new 33"km2's. over the course of 2012 i added a front locker and a posi-lock and some prp suspension seats and wheeled it up until oct when i was rear ended on the interstate and totaled the jeep. well i only had liaility and the guy that hit me had no insurance so i set forth to rebuild it out of my own pocket.
before the wreck.
http://i94.photobucket.com/albums/l102/redneck23ms/009-2.jpg (http://s94.photobucket.com/user/redneck23ms/media/009-2.jpg.html)
after the wreck
http://i94.photobucket.com/albums/l102/redneck23ms/001-21.jpg (http://s94.photobucket.com/user/redneck23ms/media/001-21.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/002-16.jpg (http://s94.photobucket.com/user/redneck23ms/media/002-16.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/Resize_P10-07-12_08-0910007A0.jpg (http://s94.photobucket.com/user/redneck23ms/media/Resize_P10-07-12_08-0910007A0.jpg.html)
picked up this for a donor
http://i94.photobucket.com/albums/l102/redneck23ms/001-22.jpg (http://s94.photobucket.com/user/redneck23ms/media/001-22.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/003-14.jpg (http://s94.photobucket.com/user/redneck23ms/media/003-14.jpg.html)

[redneck23ms]

got the body swapped and painted
http://i94.photobucket.com/albums/l102/redneck23ms/101_0232.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0232.jpg.html)
one of the rear leafs was bent from the wreck so i picked up a pair of waggy main leafs and used them to stretch the rear out 2.5" and had to do a bit of trimming
http://i94.photobucket.com/albums/l102/redneck23ms/101_0282.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0282.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/DSC_0196.jpg (http://s94.photobucket.com/user/redneck23ms/media/DSC_0196.jpg.html)
then i picked up this roll cage used and painted it and swapped it in.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0300_zpsc626631a.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0300_zpsc626631a.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0305_zps7cc0a413.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0305_zps7cc0a413.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0307_zpsba1eab43.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0307_zpsba1eab43.jpg.html)
cut down my sound bar that was broken from the wreck to work with the new cage
http://i94.photobucket.com/albums/l102/redneck23ms/101_0316_zps4f9265f9.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0316_zps4f9265f9.jpg.html)

[redneck23ms]

that gets me to the point where i am now. a month or so back i picked up 2 pair of dana44s and 9". sold one pair and have been collecting parts to build the other set. so far i have picked up 5.13,5.14 gears for the axles, install kits for both, a set of ctm u-joints for the front axle and a detroit for the rear. still searching for a front locker. also picked up all of the parts to swap the axles in including spring perches, u-bolts and plates, hiem joint steering setup, pinion guard for the 9", chromo shafts for the front, waiting on a solid diff cover to be shipped for the front, a set of wheels to match the new bolt pattern, a warn gas tank skid that i will have to notch to clear the rear diff due to the stretch and some bushings to tie the cage to the frame. and probably some other stuff that i have forgotten.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0344_zps4c886332.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0344_zps4c886332.jpg.html)

http://i94.photobucket.com/albums/l102/redneck23ms/101_0350_zps8bb7ffb4.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0350_zps8bb7ffb4.jpg.html)

http://i94.photobucket.com/albums/l102/redneck23ms/101_0351_zps0ac712ad.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0351_zps0ac712ad.jpg.html)

http://i94.photobucket.com/albums/l102/redneck23ms/101_0349_zpsb450bddc.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0349_zpsb450bddc.jpg.html)
took several cutoff wheels and wire wheels to get the axles cleaned up
http://i94.photobucket.com/albums/l102/redneck23ms/101_0357_zpsb9bd9041.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0357_zpsb9bd9041.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0361_zpsa787494e.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0361_zpsa787494e.jpg.html)

http://i94.photobucket.com/albums/l102/redneck23ms/101_0362_zpsac9722ba.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0362_zpsac9722ba.jpg.html)
that pretty much puts me where i am today. i'm painting the axles and associated parts today and hope to get the gears installed next weekend and maybe even get the axles swapped in.

[dscowell]

That cage is a flippin beast! You have done some good work!

[redneck23ms]

got both axles cleaned up and painted and pretty much all of the other parts painted except the rear axle shafts. also painted the wheels on one side. going to do the other side tomorrow. the axle housings, rear third member and wheels are rustoleum hammered black which is really more of a grey color. rear brake backing plates and drums are painted with high heat black paint. and can see the front caliper brackets and knuckles are neon green. the steering will also be the neon green once it is installed.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0368_zps28cde6c2.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0368_zps28cde6c2.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0365_zps0a8e34a2.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0365_zps0a8e34a2.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0364_zps423b4083.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0364_zps423b4083.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0363_zps928ec1e0.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0363_zps928ec1e0.jpg.html)

[Popsgarage]

rustoleum hammered black which is really more of a grey color.

But it looks good and lasts forever. I paint almost everything I build with that stuff.

[redneck23ms]

we got the gears/lockers installed yesterday. took quite a bit longer than i expected so didn't get anything else done. may go tomorrow and finish assembling the axles. if not it will be next weekend before i get any more work done on it.

[redneck23ms]

got the axles assembled friday. hoping to get them installed this coming saturday.
http://i94.photobucket.com/albums/l102/redneck23ms/Resize_P08-23-13_15-2310008531_zpse43bcbae.jpg (http://s94.photobucket.com/user/redneck23ms/media/Resize_P08-23-13_15-2310008531_zpse43bcbae.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/Resize_P08-23-13_15-23_zps08ff46b3.jpg (http://s94.photobucket.com/user/redneck23ms/media/Resize_P08-23-13_15-23_zps08ff46b3.jpg.html)

[xaza]

Getting closer, I know you are excited

[Mr6dwg]

All I can say, is nice work! I wish I had your knowledge. Getting that all back together and putting it on the road must be a nice feeling of great accomplishment.

[redneck23ms]

didn't get to install the axles this weekend. but i did get my winch installed that i got for a birthday prize. went back to barnes4wd for the winch plate. install was pretty easy other than my inability to drill holes in the proper place and i had to notch the winch plate for my tow hooks . and then today i replaced a broken leaf spring center pin bolt. pretty sure its been broken for a couple weeks. just never got around to fooling with it since i was planning to have the axles out this weekend i was going to fix it then. anyways that is all. going wheeling tomorrow.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0369_zpsde84112d.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0369_zpsde84112d.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0370_zps4cbde3ca.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0370_zps4cbde3ca.jpg.html)

[Jim]

Progress!

Enjoy wheeling tomorrow...

[Popsgarage]

Have fun.

[redneck23ms]

the new axles are in. the front ended up being offset to the passenger side a little as i didn't want to cut into the housing any or cut out the perch and weld it to the cast center section but it will be fine. still have to do some painting and figure out what i'm doing with the parking brakes. will need to put in some shock hoops and new shocks in the front and new shocks in the rear as well some time in the future. pics aren't the greatest but here goes.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0409_zpsa8df50ae.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0409_zpsa8df50ae.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0410_zps89d6533f.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0410_zps89d6533f.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0415_zps51161ed9.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0415_zps51161ed9.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0414_zps57d93bf7.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0414_zps57d93bf7.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/101_0416_zps22c9386e.jpg (http://s94.photobucket.com/user/redneck23ms/media/101_0416_zps22c9386e.jpg.html)

[Popsgarage]

i didn't want to cut into the housing any or cut out the perch and weld it to the cast center section

You don't necessarily have to do either. Order a pair of Dana 44 perches from RuffStuff and ask Dan to trim the drivers side and cut the factory perches off and weld the new drivers side closer to the center section and move the passenger over the same distance to match. Here's a pic from Rough Country to illustrate what I mean. This is a set of Dana 30 spring over perches from Rough Country. Dan at RuffStuff did the same thing for me for about $10 or $20 less if I remember correctly. He's done the same for the 44 housing perches he sells.
http://www.roughcountry.com/images/jeep_699.gif

[redneck23ms]

yeah i have seen those 100 times but didn't even think about it at the time. for now its going to stay offset. may do that later and fix it

[Popsgarage]

Did it with my spring over 30 under the wife's "94 S-10 Blazer and it was super simple. And the three pin locations he places in the perch means you can fine tune the location of the axle. Forward 1", factory, or back 1".

[redneck23ms]

yeah the perches i used are from barnes 4wd and they have 3 holes as well

[Popsgarage]

Lookin' good, by the way. You've brought it a long way from when it was laying sideways on the highway.

[JAB]

love the jeep, I have a 92 as well, do you happen to have any extra parts left such as a replacement axel for my d 35 or any kind of lockers for the front d30?

[redneck23ms]

i don't have any axles for it anymore. but you can get one from a cherokee. only parts i have for it are a shackle reversal kit. a soft top, a bikini top, steering column, and some small stuff like stock shackles etc

[Popsgarage]

Josh, here's a recent post about a D35.

http://www.frontrange4x4.com/forums/showthread.php?20657-TJ-Dana-35-with-ARB-and-4-56-gears-300

[redneck23ms]

haven't really done anything to the jeep in months other than get a new set of 35" km2's and installed a fire extinguisher. last week i picked up a used set of beadlocks. they are 15x10 eaton's. the rings have a bit of rock rash but nothing too bad. they also only have 16 bolts per ring which has caused some of the bolt holes to become flared a bit. i am going to drill them for 32 bolts and paint the outer rings before i install them. haven't decided on a color yet either the body color OD green or the flourecent green. may try one each color and see how they look. these wheels will move the tires out about 3" on each side to put me at an overall width of around 83" outside of the tires.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0462_zpsbf6a0370.jpg
http://i94.photobucket.com/albums/l102/redneck23ms/101_0463_zps792fb991.jpg

[Kevin]

Really Neat ride. I'm glad you were able to salvage what u had left
Glad your ok from the accident........

[redneck23ms]

started working on my beadlocks today. got 2 of them done other than paint. still have to straighten out the rings and drill the other 2. drilling all of those holes with a hand drill brings the suck. each of the 16 extra holes i'm doing gets drilled twice. once for a pilot hole and then with the full size. going to work on the other 2 after my break. then maybe wire wheels the rings. still haven't decided on a color. leaning towards body color for the rings. then wheels themselves will stay black as they are in great shape. also these wheels originally had nutserts but over half of them were already gone so i knocked the rest out and will replace them with nuts and washers.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0466_zps1695de3f.jpg
http://i94.photobucket.com/albums/l102/redneck23ms/101_0468_zpsea8cb124.jpg
http://i94.photobucket.com/albums/l102/redneck23ms/101_0465_zpsa89bdb10.jpg

[redneck23ms]

picked up a used box4rocks doubler today. it basically uses the front half of a np231 transfer case, which is where the planetary reduction part is. and then you can bolt another np231 or a dana 300 to the back of it. mine came with 2 broken dana300's. hoping that i can make 1 good one out of the 2 broken ones. if not i still paid less than half of what just the kit costs. going to try and tear into the dana 300's tomorrow and see what i've got.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0469_zps2f895c86.jpg
http://i94.photobucket.com/albums/l102/redneck23ms/101_0470_zps0560a567.jpg

[redneck23ms]

mmmmmmmmmm yummy goodness right here. but the good news is that both output shafts are good in this case so i should be able to swap them into the other one and have a working dana 300.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0471_zps8e2109a5.jpg

[redneck23ms]

well i ran into a bit of a snag. the donor case turns out to be from 1980. in 1980 the rear output was shorter than the later models so the rear output shaft won't work for me. the front one will still work so it wasn't a total loss. now i either need to source a longer rear output shaft or just pony up the cash for a 32 spline HD rear output setup. which is around $400.
http://i94.photobucket.com/albums/l102/redneck23ms/101_0472_zpsbbfdf1cb.jpg


http://i94.photobucket.com/albums/l102/redneck23ms/101_0473_zps312397d4.jpg


and this is what came out of the case lol
http://i94.photobucket.com/albums/l102/redneck23ms/101_0474_zps9677a978.jpg

[Hypoid]

now i either need to source a longer rear output shaft or just pony up the cash for a 32 spline HD rear output setup. which is around $400.

WOW! I was getting ready to list a D-300. Maybe I should bump the price... ;)

[redneck23ms]

i had been thinking about selling the jeep and possibly getting a 4 door jk but i have pretty much decided to keep it and get a tow rig/daily driver. anyways i picked up a new to me bumper a couple days ago. this bumper was built for a yj but that particular yj had a custom rear crossmember so some of the bolt holes were different. i ended up having to drill 4 new holes in the bumper and slightly modify a few in my rear cross member. but i got it bolted up tonight. 4 of the bolts were tough as they are between the vfuel tank and the crossmember = no room. but i got them all in. it is pretty sturdy and has a swing out tire carrier and d-ring mounts welded on both sides of the 2x4 tubing that its made out of. i just need to add a trailer receiver tube and it'll be good to go. pics show the old thin/bent bumper and the new one.
http://i94.photobucket.com/albums/l102/redneck23ms/Mobile%20Uploads/image_zpsc5d6d841.jpg (http://s94.photobucket.com/user/redneck23ms/media/Mobile%20Uploads/image_zpsc5d6d841.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/Mobile%20Uploads/image_zps2361cfec.jpg (http://s94.photobucket.com/user/redneck23ms/media/Mobile%20Uploads/image_zps2361cfec.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/Mobile%20Uploads/image_zpsad863528.jpg (http://s94.photobucket.com/user/redneck23ms/media/Mobile%20Uploads/image_zpsad863528.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/Mobile%20Uploads/image_zps3632f497.jpg (http://s94.photobucket.com/user/redneck23ms/media/Mobile%20Uploads/image_zps3632f497.jpg.html)
http://i94.photobucket.com/albums/l102/redneck23ms/Mobile%20Uploads/image_zps5fbebd40.jpg (http://s94.photobucket.com/user/redneck23ms/media/Mobile%20Uploads/image_zps5fbebd40.jpg.html)