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Old 08-01-2016, 12:30 PM
tworley tworley is offline
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Default My build

Just a thread following my build.

Purchased a 97 TJ Wrangler in July 2014. Always wanted a jeep and after selling a truck, I figured now was the time. I found this jeep local to me in Colorado. Been a CO rig all its life. This is what it looked like


4" Superlift with 35s, dana 30/35 combo with 3.55 gearing. I wasnt aware that the D35 was such a poor axle, the thing that sold me was how clean the jeep was, not a scratch underneath, no rust. Literally had never been offroad.

First change was getting rid of the 35" tires. They were over 6 years old and clearly the rig was not set up to run 35s quite yet. I opted for 33" duratracs


2nd upgrade--Found a guy on wranglerforum who posted about selling his rubicon axle in the near future, subtle comment that not to many people noticed. Lo and behold, he was only 45 minutes from me. I called him, made a deal, and was ready to hit the trails soon. He also helped me install it in his garage. With that purchase, I added an Advance Adapters SYE and metalcloak adjustable control arms and track bars to get everything dialed in and to lose the tcase drop that the jeep originally came with.




And my first wheeling trip with the axle suspension parts


A few more wheeling trips






Fast forward to 2016 and my big purchase was the savvy under armor. Included a 1" motor mount lift, 1.25" body lift, tcase skid, and gas tank skid.


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Old 08-01-2016, 12:31 PM
tworley tworley is offline
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Default Re: My build

Issues arose with this. my shock bodies contacted the coil springs (not the perch), my pinion angle was 34 degrees, and my CV shaft was binding at full droop To solve this, we decided to relocate spring perches, shave the axle completely and reinstall 3/16" brackets and clocked everything to mesh with the steep angle








With all that work, I am still binding at full droop (juuuuust barely). I opted for the super short sye from JB conversions and am working on that currently. It is about 2" shorter than my current SYE which should help tremendously.
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Old 08-01-2016, 12:44 PM
tworley tworley is offline
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Default Re: My build

During a test run, I shifted into 3rd and my thumb accidentally engaged my locker Pulled the cover and found alot of gear teeth. So the hunt for a replacement started. Luckily my buddy found a brand new ARB locker on craigslist. $500! I bit the bullet and bought it. Was going to install it this past weekend when I found out the new R&P I bought (rubi locker requires thick cut gears, the ARB requires normal cut) would not work. With new parts on hand, I am hoping to get it installed this Thursday and try and get a my current DC shaft lengthened to accommodate the super short sye. Hopefully I am back on the road by next week. Ill have to burn thru a couple tanks of gas to break in the new gears and locker before I can offroad again but there is light at the end of this long tunnel.
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Old 08-04-2016, 08:13 AM
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sam025 sam025 is offline
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Default Re: My build

Looking good!
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Old 08-08-2016, 10:13 AM
tworley tworley is offline
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Default Re: My build

Had an incredibly long weekend.

JB Super short installed



The goodie found on Craigslist. New ARB for $500!


To replace the stock rubi locker (see why)


Notice the lovely chunk of metal in the bottom to the right of the ring gear? Ive learned rubi lockers dont like to be enganged while in motion.


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Old 08-08-2016, 10:16 AM
tworley tworley is offline
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Default Re: My build

We could have had this done earlier, but some mistakes by 4wheelparts, I received thick cut gears for a stock locker when I actually needed normal cut gears. After a bit of back and forth, I finally got the correct ring and pinion. Then the next issue arose. We had the wrong size ring carrier bolts. Another trip to town delayed us. Theres a reputable shop here in CO called Edge Automotive who had the correct ring gear bolts, for free Finally, we started making progress.

Old parts removed.


The old pinion nut took its toll on this ratchet


Cutting drain slots


Carrier bearings in place along with ring gear (and the correct ring bolts)


Installing the setup race and pinion bearing



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