02 turbo TJ Frame/Suspension replacement

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Made some progress forward this morning.

removed the old, sort of, arb locker wire harness attempted more getting that manifold off of fab bracket, gave up, need new drill bit set, a bench drill press is on my tool list.
just started pondering how to piggy back the tuner cpu, in cleaner looking manner
decided to remove dual battery switch and mount the aux beam relay box there when I start that project
Rock lights came in today and some 1/4” npt fittings for ARB
And…..finally I removed my rear bumper, the thing is tweaked. I want to go with bumper delete look and I am. My GEN RIGHT wish list just grew.
And yes this put off Pismo trip, My wife has a bunch of work coming up with World Cup soccer coming soon as well.


I thought it would be an easy removal…..NOT!!! Has to grind some welds. It’s not pretty, but same on both sides….HA.
The bumper would make a nice bumper air tank. It is NOTgoing back on this rig. The red wire loose near fire wall is my for amp feed had temporally strapped to old arb harness.
Various Die grinders are on my tool list as well.
I am on a fencepost on getting that compressor bracket that mounts off of the brake booster.
Time for a nap.

 

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To start, I am going to get the drop down tire carrier bumper plate next month. It will be a nice drive to pay them a visit, WITH CASH ONLY FOR BUMPER PLATE, NO CREDIT CARD, when I visit. I would like to have hitch receiver welded on plate as well.

 

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At this point with the rear end issue, I want to get 5” stretch kit. There are only two that I can find, Barnes and Clayton. GR 8” is over my bounds and pricey and more labor
Any Suggestions?

 

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8.8 for 02 TJ on EBAY, its out from Colorado.
I still moving forward with the drop down tire carrier plate next month, tire carrier is currently on sale, not enough cheddar in jeep fund for that now unfortunately.
The 3” lights I got for rear bumper will now go on a-pillars, a 12” light bar on top of front bumper hoop and fog lights on front bumper. Rock lights, sending back.
Aux beam was not my desired brand but they're affordable option for now, trying to stick with US made stuff the best I can.
Plan to install temporary fuel check valve tomorrow, then bring that bracket to my buddy's shop to use the drill press.
He asked me to go down to the de-sol Delmar jeep fest in two weeks, cant swing that, That’s this rigs old stumping ground. I removed six bumper stickers for that event

 

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I managed to drill out the manifold mount screws to bracket. I gave a whirl, it does not fit as envisioned and hotter in that corner I would imagine.
I will order booster mount bracket with the amazon returns.
Debating now with inline fuel check valve. Dropping the tank is required to install drop down carrier plate. GR Fuel tank access panel is on wishlist.

 

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Should roll in early next week

 

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I have abandoned any trips to Gen Right anytime soon. I do intend going with them but not getting the drop down tire carrier. Thinking bumper plate with tow points, corner guards and rocker guards from them when on sale. The GR swing out carrier is nice but pricey. The carrier from Rusty’s is a consideration. No Jeep trips anytime soon with current gas prices, crazy here in so cal. I have a full tank.. I need to focus on what needs to be wrapped up. I did tap into GR fund to get a transmission cooler, couldn’t resist the price. I intend to get a higher capacity Transmission pan and temp guage next month. I have everything to flush out cooling system and replenish.
I am planning on venting hood and installing an oil cooler for turbo.
It reached 93 degrees today!

The ARB compressor bracket should finally roll in tomorrow.

 

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I not sure to be fit to be tied or relieved knowing now what to do with, “I don't know where its going to rebuild”
This thread will merge into a new thread, 02 modified TJ frame swap?
I finally realized that my current frame is bent and or twisted driver side rail.
All has changed now!
I could try to maybe get frame repaired, but I want the FABTECH lift out now.
It is not safe ride on road.
Too much has been hacked off of frame, so a replacement frame is my route now.
I can source a salvaged frame from Jeep Depot?
Or find a way to pay for a TDK frame?
I am leaning towards a MetalCloak suspension set-up at this point.
I do have moments to just throw in towel and get rid of this rig. Best just to part it out?
But…..I cant, I am hooked

 

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Ok, after I have calmed down with frame discovery, the damage is not where I thought it was until I studied some good photos of a rolling frame from Jeep Depot.
Big difference from right to left where factory front spring/shock mount is welded on. Regardless frame is bent/deflected up a 1/2”on the driver side.
My plan is down Jeep soon and start my frame swap.
First get garage ready.
replacement frame from Jeep Depot, $12503
Rock Jock 4.0” Pro short arm kit with 1” body lift is what plan on
Rock Jock anti sway
Shocks?
Change final drive ratio 4:56 maybe 4:10 and run 315/75r17
I ordered the Quadra Tech rain cover to keep Jeep outside when need to, until time to swap.
Got my wish build it my way, gratefully I have gotten my wife’s blessing to proceed with project.
I hoping to have a replacement frame in my garage in May.

 

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Maybe, I should say May of next year? For frame? Way things keep adding up. I must not put self on a schedule, need keep an a check on my health.
I decided first and first and foremost now, is do a compression check on engine and see if still in spec, should have have done it the at get go. Been running a little rough lately. 52k miles, I believe turbo was added to the Jeep in 05-07 time frame, After it came to the states from Hawaii.
Best to know where it stands, before a frame swap, it is running strong, uphill no issues, boost seems to be functioning correctly.