James & The Sahara Build Thread

For future reference...cast iron doesn't like to be bent...it's very brittle, as you found out. Sucks that you had to go through that, especially after having the new one all painted.
 
I did want to add now that I have settled down I did get a couple of things done today. I was very careful getting the passenger side brakes and rotor in using CRC Brake Quiet all over the place apparently. I also centered my Savvy DA control arms which wasn't too difficul
For future reference...cast iron doesn't like to be bent...it's very brittle, as you found out. Sucks that you had to go through that, especially after having the new one all painted.
you would think I would know my metal properties by now eh? No worries it was bent before I started lol.
 
Hello everyone! I was a long time lurker and finally decided to join the forum. I have been a member of other forums, but really like the vibe that exists here. I will be starting a log or "Build Thread" of everything that occurs with my jeep from here on.

Short Introduction of myself: I am a student at Auburn University (You can tell this will be a budget build hahaha) studying Computer Science. I purchased this TJ after selling my motorcycle in the summer of 2016 from a dealership in atlanta for next to nothing. When I bought the TJ it had the original soft top on it (Torn and all) and was nearly bone stock. The only modifications the previous owner did was purchase an ARB Deluxe Front Bumper (You rock!) and a really crappy roof rack that after the ride home I ended up getting rid of it :D.

Here is what I have done to the Jeep up until now:

1998 Jeep Wrangler TJ Sahara W/ Stock Suspension, Dana 30/35 3.07 5MT.
  • Replaced all of the stock Audio Equipment is Polk MM Speakers and installed a Pioneer 8700BHS.
  • Replaced the tattered old carpet with Bedrug Front & Rear Carpet.
  • Replaced the crappy Rally Spread Lights that came with the TJ for a set of KC Fog's I found on Craigslist for free.
  • Replaced the original MOPAR soft top with a 1998 TJ Tan hardtop with factory tint and equipment.
  • Installed a Gobi Roof Rack w/ Quick Release & Two ladders.
  • Installed a set of JW Speaker 8700 Evolution 2 Headlights.
  • Installed a 40" Cheapo Light bar I found on Amazon for next to nothing.
  • Installed GraBars for the Driver and Passenger.
  • Installed a MOPAR TJ Add-A-Trunk I found on ebay for $50.00.
  • Installed a set of WeatherTech Front Floor Liners
  • Wrapped my Steering Wheel and some other interior pieces with 550 Paracord, cheapo version of a steering wheel cover and quite like it!
As she stood the day I picked her up with the dealership with my little brother (Wow I failed to take any decent pictures of the jeep, oh well here's a picture of her on a lift while I checked out the integrity of the frame):
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As she stands today:
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Welcome! I also sold my bike for a Sahara tj, haha! Looks great, love the color.

Sent from my SM-G950U using Tapatalk
 
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Lots of updates today! Got an early start and with the help of a peer we removed the steering knuckle from my old Dana 30 axle and installed it in place of my broken HP30 knuckle:

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Yes we have a mounted brake caliper with no hammering!

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The ball joints that Motobilt installed (Mevotech??) had significant play in their mounts and weren't pressed in by any means just resting in the mount (See video below to see how easy they are removed):

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Since we had to remove the steering knuckle, it revealed Motobilt didn't clean very much of the dirty inside of the axle tubes or the differential cover. No worries I cleaned them out the best I could with brake cleaner and air:

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I don't really know much about the gear wear/patterns but this is how she was received:

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For whatever reason Chrysler used splined Torx bolts for the sway bar bolts which made this a 1 hour ordeal of propane heat and hammering to remove (I can't imagine that painting over them helped me any either):

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Starting to connect everything back and started jumping on the vehicle to center the suspension:

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Differential cover reinstalled with LubeLocker. Filled her up with 80-90 gear oil from Napa and the front was finished!

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Her front end is really starting to look good! :D

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Last update for this weekend! Got the dana 35 dropped:

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Got the old hard lines swapped over, surprising the hard lines fit the Dana 44 better than the 35:

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Got the Dana 44 installed:

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Sadly as always ran into a setback that let me stop for the day. The previous owner of the Dana 44 was so kind to leave the sheared off bolt remains in the pinion yoke so I couldn't reinstall the driveshaft (Can't believe I didn't notice it before). I am going to check around and look for a replacement as I have been told that will be hella easier than an ezout of that size:

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What is left:
  • Cut & flare both ends of hardline to allow connection of BMB disk brakes.
  • Remove & install BMB parking brake mechanisms.
  • Install Teraflex E-Brake cables.
  • BMB Dana 44 Rotors installed.
  • BMB Dana 44 Calipers Installed.
  • BMB Dana 44 Pads installed.
  • Replace Spicer Yoke on the Dana 44.
  • Connect MC Track bar.
  • Remove Dana 44 Diff Cover, clean up surfaces, install LubeLocker, & fill to fill plug.
  • Flush & Bleed entire brake system.
  • Drive & break in all components appropriately :D.
I am celebrating though, I got both axles off & on in the 4 days I had with only minor setbacks. I go back to school tomorrow so my working on Jeep time will be very limited during the week. Tuesday I am hoping to knock out a majority of this, finishing it all hopefully by Thursday. Only time will tell!
 
I applaud your persistance. I hope you got a real good deal on your axles. Seem a bit "dirty". Anyway I'm excited for you. Being an owner of a 98 Sport that I did an axle swap in my driveway I feel your pain and your excitement
Can't wait for your test drive.
 
I applaud your persistance. I hope you got a real good deal on your axles. Seem a bit "dirty". Anyway I'm excited for you. Being an owner of a 98 Sport that I did an axle swap in my driveway I feel your pain and your excitement
Can't wait for your test drive.
$40 for the HP30, $800.00 for the Dana 44 :D. Thank you so much and me too!
Keep up the consistent work James. Looking good.
Thanks bud! Glad I got the super big stuff out of the way.
 
You're making great progress Jimbo! Could you drill out those yoke holes to accept u-bolt style clamps? They'd be stronger.

https://www.amazon.com/dp/B000CKN6YA/?tag=wranglerorg-20
Since you have brought this up I am seriously considering it. Before doing anything I am going to contact motobilt in the event I can’t drill them out & ask: can I replace the yoke without affecting the gear setup. More to come.

Edit: Looks like I will try drilling but can remove if needed:

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Another update: Got some quality time with the Jeep after class today. I planned my cuts on my hard line and started cutting/double flaring - but my tool rented from O'Rielly broke upon practicing on the brake line (Go figure). The true cut will be behind the tab no worries. No other auto parts store in town had a rentable double flare kit so I decided to pass the line to someone else. I have a buddy that works in as a mechanic so I just dropped the hard line off with him and awaiting to receive it.

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I did get most of the braking equipment installed (That newfound bling from Black Magic Brakes ;) ):

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This part deserves pictures, but I failed to get them lol. I got the Metal Cloak rear Track Bar and relocation bracket on, looks great (See that one sad photo below) & I'll share more about it in my next update post :).

Next my buddy brought over a quality set of Jobber drive bits and we went to town on the Dana 44 Yoke. All 4 holes have been drilled out and sadly no auto parts store in town has a u-bolt that is long enough to get a nut on. I have ordered two different longer ones from Amazon and one of them will hopefully fit (They are coming 1 on Thursday, one on Friday).

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Finally, tomorrow or early Thursday I will get the LubeLocker installed in the Dana 44 & fill it with fluid, run the new E-brake cables, & install the hard line. Once the brake line is on I can bleed the system with my new Mightyvac 8000. Then connect the rear driveshaft. After all that I should be good to go to start the break in period for brakes & gears! :D
 
Yesterday i got the new radio in! Got a working cassette player so I have my Sirius XM again! Feels good to have tunes again, some quality went into refurbing this thing. The aux is wired into one of the buttons so the button no longer function. You can listen to aux by inserting a cassette and having an input plugged into the aux port. If nothing is in the aux port the cassette plays. Sound quality is surprisingly good, I do have intentions of amping the speakers again and doing a center console sub.

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I also dropped off the axles to get black glass blasted and primed/painted. I should be taking em to Motobilt next week.

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I finished the Gentex Mirror wiring and it works great. Love having a dimming mirror driving with no rear window at night.

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My savvy front lower control arms come tomorrow and ECGS’ UCA Bushing came today (Which is really just a Moog). I ordered this because price was right and came with the outer sleeve which most of them didn’t.

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Where did you get the radio?

I'm interested in putting a factory radio in my TJ. However, like you, I want an aux input.
 
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