View Full Version : 97 ZJ Garage to Trail Project
Danimal
May 15th, 2017, 10:23 AM
I bought a ZJ that had been sort-of built as a crawler, but had some problems. It had the one major upgrade that I wanted, and that was a long arm suspension kit with sway bar disconnects. It had an OX locker in the front (just found out it is bad) and needed a rear diff (kinda think these issues might be related.) It was not driving when I bought it, but it started right up and runs fantastic. The rest of the jeep is in perfect condition, so I figure that it will make a good project to get the family into the outdoors and off road.
My goal is to have a safe reliable Jeep that I can drive from my house at hwy speeds and get into some fun trails with friends. Not planning on running crazy crawling adventures, but I want it to be rugged and reliable enough to get out of a sticky situation if needed. I think that the ZJ with the 5.2 is a good platform for both on and off road stability, and it has the power to get through some tough stuff if needed.
Last fall: Replaced the shot Dana 44A with a Ford 8.8. The bearing blew up and the carrier shifted over ahd ground away the side of the aluminum journal, so probably not a great idea to rebuild it. I had the axle built by SFF customs, but I am probably going to open it up after reading some reviews and noticing that it is already noisy. Here are some install pics.
Danimal
May 19th, 2017, 09:03 PM
Tore the NP249 out, and took the new NP231 apart. Everything was in really good shape, but the plastic cage on the main input bearing had shattered. I am not sure why anyone would put a plastic cage on a bearing... taking it out was really smooth. I had the 249 out in about 30 minutes and it took me about 4 hours today to completely strip and clean the 231. I put in all new seals. Now I just have to wait for the input bearing to put everything back together.
Brian
May 19th, 2017, 10:16 PM
Any thoughts on going SYE on the 231 since you got it out anyway? I have a NP241 and did the conversion and it was pretty easy.
xaza
May 19th, 2017, 11:01 PM
A note on the SYE, Bill's Englewood Drive Shaft is a member on here and offers a good deal on SYE and drive shaft. Quick turnaround and excellent service with incredible quality. I will leave a link to him at the end for when you are ready. I ran 6" lift on my XJ and was replacing ujoints on a regular basis until installing the kit. I have considered this swap for my 98 ZJ but have grown used to the AWD and it really launched nice at the track with it.
http://www.billsenglewooddriveshaft.com/
Danimal
May 20th, 2017, 10:42 AM
Any thoughts on going SYE on the 231 since you got it out anyway? I have a NP241 and did the conversion and it was pretty easy.
I want to, and might have the cash to do it now. I found the front axle that I needed for cheaper than I thought and I am picking it up today. I wanted to do the swap from the beginning, but the boss limited the funds.
Danimal
May 20th, 2017, 10:43 AM
A note on the SYE, Bill's Englewood Drive Shaft is a member on here and offers a good deal on SYE and drive shaft. Quick turnaround and excellent service with incredible quality. I will leave a link to him at the end for when you are ready. I ran 6" lift on my XJ and was replacing ujoints on a regular basis until installing the kit. I have considered this swap for my 98 ZJ but have grown used to the AWD and it really launched nice at the track with it.
http://www.billsenglewooddriveshaft.com/
I am going to send him a message now. Thanks for the info.
Danimal
May 20th, 2017, 10:43 PM
Got a new front axle today. It is a dana 30 HP with Aussie Locker. I would like a selectable locker in the front, but I will make due. It is not a daily driver. I pulled it apart and everything looked really good. I started to transfer over parts to the new axle. Jeep looks pretty naked without any front suspension.
Danimal
May 20th, 2017, 10:51 PM
Got a question: The long arm lift kit has some eccentric bolts and slotted mounts that were welded to the old axle. It that a critical adjustment for the lift? I would rather just hard mount it and make very accurate measurements to align the axle. I still have overall length and angle adjust-ability, though it will be more tedious.
Basically it is this part (https://www.4wd.com/p/rubicon-express-heavy-duty-control-arm-brackets-re9995/_/R-BKTG-RE9995?utm_source=google&utm_medium=cpc&utm_campaign=shopping&emlprox=out&ppcfon=1&gp=1&scid=scplpR%2FERE9995&sc_intid=R%2FERE9995&gclid=CN2F-oeKgNQCFUhqfgodfF8AjQ) welded on in place of the lower control arm mount. You can adjust it back and forth without threading in the rear insert. Not sure I want or need that adjustment. I am going to read up on it, but any advice would be appreciated.
Java
May 21st, 2017, 12:40 AM
nice axle upgrades! I recently resealed my NP231 and switched it to Mobil1 10w30. I got the idea here: http://www.novak-adapt.com/knowledge/transfer-cases/np231
xaza
May 21st, 2017, 02:57 AM
That is a cam bolt setup. I chased issues with the cam bolts coming loose on my truck for a long time. Eventually we got them tight enough to stay in place. It will have a bolt with a flat side and an offset washer of sorts. Here is a picture of the hardware in case you are missing them.
http://www.spohn.net/shop/2003-2011-Dodge-Ram-4x4/Front-Lower-Control-Arms-Cam-Bolts-Package-2003-2009-Dodge-Ram-4x4-2500-3500.html?gclid=Cj0KEQjw9YTJBRD0vKClruOsuOwBEiQAGk QjPy_wouMEt7wfXgbswV6kuzT84p7ZDeha47pMzVero7kaAvkz 8P8HAQ
Hypoid
May 21st, 2017, 11:05 AM
Got a question: The long arm lift kit has some eccentric bolts and slotted mounts that were welded to the old axle. It that a critical adjustment for the lift? I would rather just hard mount it and make very accurate measurements to align the axle. I still have overall length and angle adjust-ability, though it will be more tedious.You have it right, you can adjust caster with your aftermarket arms.
It is hard to tell in the picture, but you want to reinforce your passenger side upper control arm mounting bracket on the replacement axle. I fixed a stock bracket that had ripped off using a similar control arm set-up.
http://www.frontrange4x4.com/forums/attachment.php?attachmentid=45260&stc=1&d=1495338226
Danimal
May 21st, 2017, 05:53 PM
That is a cam bolt setup. I chased issues with the cam bolts coming loose on my truck for a long time. Eventually we got them tight enough to stay in place. It will have a bolt with a flat side and an offset washer of sorts. Here is a picture of the hardware in case you are missing them.
http://www.spohn.net/shop/2003-2011-Dodge-Ram-4x4/Front-Lower-Control-Arms-Cam-Bolts-Package-2003-2009-Dodge-Ram-4x4-2500-3500.html?gclid=Cj0KEQjw9YTJBRD0vKClruOsuOwBEiQAGk QjPy_wouMEt7wfXgbswV6kuzT84p7ZDeha47pMzVero7kaAvkz 8P8HAQ
Thanks, That is something that I was worried about. I think that I am just going to get rid of them and make adjustments on my control arms. Mostly if I am torquing and flexing I don't want to worry about them rotating and causing problems. Those are exactly the bolts that were on there.
dieseldoc
May 21st, 2017, 07:00 PM
Do the she now, and you might want to do the 2wd-lo shift conversion.
Its a few hundred bucks but we'll worth it.
Bills does a nice drive shaft for sure.
Danimal
May 22nd, 2017, 02:41 PM
Do the she now, and you might want to do the 2wd-lo shift conversion.
Its a few hundred bucks but we'll worth it.
Bills does a nice drive shaft for sure.
Wow, I did not even know that the 2Low kit existed.
I got my new axle all checked out and most of the way installed over the weekend. I might have the money leftover for the doing this. But now I am getting a little antsy to get the jeep done and get out and drive it.
dieseldoc
May 23rd, 2017, 11:09 PM
I feel ya.
My 3 day weekend is and axle rebuild/regear wrench test.....got to get this stuff done so we can wheel the anniversary run!
Danimal
May 24th, 2017, 09:26 AM
I feel ya.
My 3 day weekend is and axle rebuild/regear wrench test.....got to get this stuff done so we can wheel the anniversary run!
I got the axle under the jeep and roughly aligned on Monday night. I think that the parts for the NP231 should be here this week, if they are I should be able to button everything up and get an alignment.
What / when / where is the anniversary run? I want to get a couple hundred miles on everything and change the fluids before I start really wheeling it, hopefully I can get that done and start hitting the trails with some of you guys.
Stu
May 24th, 2017, 10:47 AM
Looks good man, you're making some great upgrades. In addition to the brace Hypoid mentioned, you might consider some Lower control arm mount Skids. The LCA mounts are easier to bend than you'd think and adding skids does wonders for keeping your mounts straight and suspension geometry in line.
Danimal
May 27th, 2017, 11:37 PM
Well today was a productive damn day. I got the main input bearing for the NP231 so I assembled it and got it ready to install. While it was drying I finished up the front end and got brakes and steering installed. I still need some lock nuts for the steering, but I will get them tomorrow if ACE is open.
Danimal
May 27th, 2017, 11:42 PM
I then got the NP 231 installed and replaced the rear main seal on the transmission. That was a little more fun for one person than I was planning on having, but it is in there working perfectly. One thing to note about changing the wiring for the transfer case swap. I have a 1997 ZJ limited. Not sure where things changed, but the center console was screwed to the dash board inside behind the glovebox. I had to pull the whole thing to get the cover off. It was not too bad all things considered, but don't try to pry the black bezel off to get to the main display behind. After that it was just a mater of finding the plugs to swap.
Danimal
May 27th, 2017, 11:49 PM
I got the jeep out of the garage today and drove it around the block to let the suspension settle. Not going to lie, 2WD is awesome and I do not even hear the Aussie Locker at all. Everything feels awesome!
Next things that I need to do are:
1) Upgraded Sway Bars
2) Armor under the transmission and transfer case
3) armor for lower control arm mounts
4) rebuild rear differential
5) SYE and drive shaft
dieseldoc
May 28th, 2017, 07:48 AM
Nice to here you got it running.
Amazing the difference from the awd to the 2wd.
When you do the sye do the 2wd-lo mod.
For your skidplates come see me.
Can build what you need.
Rear diff do you have the D44 ?
If so there is a good upgrade for the diff and gears.
It adds 44% to the strength of the D44.
JANA K4 it's a bit of work to set up, would have been half the time If they would have included the right spacer and shimms.
Any how this will stuff the JK gig pinion gears into the older D44.
Rather slick set really.
I will post pictures of mine....
The steering looks good, granted the Trac bar and drag link are not quite the same angles close,but not quite the same.
This could be some issue with bump steer.
But it a good set up.
Big and strong.
Look forward to see it at the anversery run.
Danimal
May 30th, 2017, 10:17 AM
Drove the jeep around all weekend, and could not be happier!
Here are some final pics until next time that I am ambitious enough to start tearing things apart.
Danimal
May 30th, 2017, 10:23 AM
Nice to here you got it running.
Amazing the difference from the awd to the 2wd.
When you do the sye do the 2wd-lo mod.
For your skidplates come see me.
Can build what you need.
Rear diff do you have the D44 ?
If so there is a good upgrade for the diff and gears.
It adds 44% to the strength of the D44.
JANA K4 it's a bit of work to set up, would have been half the time If they would have included the right spacer and shimms.
Any how this will stuff the JK gig pinion gears into the older D44.
Rather slick set really.
I will post pictures of mine....
The steering looks good, granted the Trac bar and drag link are not quite the same angles close,but not quite the same.
This could be some issue with bump steer.
But it a good set up.
Big and strong.
Look forward to see it at the anversery run.
I will come and get some armor sooner rather than later. I feel like it is kinda exposed, but I do not know what will fit with the long arm kit that I have installed.
So far I have a Ford 8.8 rearend, so that should be tough enough for my uses. The high pinion dana30 that I installed took quite a bit of the front driveshaft angle out, and now it is really smooth. I am not sure if the rough driving was due to the shaft angle or the fact that the front diff was slipping bearings. I had the jeep up to 75 and it was smooth quietish. Still perfect, and I think that I am going to regret not putting the SYE and shaft on there now. It will work for this summer and winter and probably will do a complete rebuild with SYE and 2 low kit next spring.
Danimal
May 30th, 2017, 10:27 AM
I think that I might get the Addco 688 rear sway bar, and some swaybar disconnects for the rear at some point this summer. I definitely have tail wag, and the front has the upgraded 1" sway bar with sway bar disconnects. The front feels great, the rear feels squishy and will roll pretty easily with the skinny little sway bar that is on there.
dieseldoc
May 31st, 2017, 08:23 PM
Think higher weight springs for the rear.
Mine was a tippy dancing goofy ride tell I put the heavy duty springs in.
The jeep is tighter now for sure.
As well once the link arms want in it got very tight.
No front saw bar at all on my TJ.
Nice you got to run it.
You still have a ways to go.
My weekend was rough.....my rear diff install was a mess as the manufacture made a big,mistake.
Danimal
May 31st, 2017, 09:52 PM
Think higher weight springs for the rear.
Mine was a tippy dancing goofy ride tell I put the heavy duty springs in.
The jeep is tighter now for sure.
As well once the link arms want in it got very tight.
No front saw bar at all on my TJ.
Nice you got to run it.
You still have a ways to go.
My weekend was rough.....my rear diff install was a mess as the manufacture made a big,mistake.
My rear diff was making more noise than I would like so I pulled it apart and measured everything. Pinion torque was 14 in lbs, no observable ring gear or carrier runout, and .010" backlash at 4 different spots. Is there anything else to check? Bearings look good, no metal in the oil, but I only had about 300 miles on it. I had it built last fall with new gears, but have not really driven the jeep much when I found out the front was all screwed up. Maybe it will wear in and quiet down? it is not bad on the drive side, but the coast side howls a little. Not sure what else I could do to quiet it down.
What was the manufacturer mistake on yours?
dieseldoc
May 31st, 2017, 09:59 PM
Sounds like you are still in the brake in.
500 miles is the normal brake in.
Mine was the manufacture was to provide a solid spacer measuring .450" I got .410"
Shimms should have been .120ish I got .080 the starting point is .100" of shimms to set preload.
So on a 3 day weekend Saturday around 4 in the afternoon I got to make my,own shimms! Sweet.
Let me tell ya I would rather watch titanic with a bunch of hormoninbalanced teenagers than do that agian!
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