04 Rubi Build

[sq8810]

I was fortunate enough to have gotten this Jeep from my father with 172K miles on it, it currently has 242k miles. Prior to starting this build, I used forums like this and youtube to replace the transmission, clutch, water pump, fuel pump, front brake rotors/pads and calipers, u-joints, and front driveshaft. I have found this forum in particular, to be the most useful and informative. I do as much of the work as I can myself and in doing so have gotten so much better/comfortable with repairs I might not have thought attempting.

So...after driving this thing for about 5 years I finally get to start a thread. All the work is done, but just wanted to share it somewhere where it would be appreciated.

The list:
Upgraded ZJ (?) tie rod ends and drag link
HD Ball joints, Wheel bearings, dust covers
Black Magic Pads, Rotors (front/rear), Calipers (front)
Poison Spyder Diff Cover
Chromoly Axle Shafts Front and Rear w/seals (ECG Supply)
Oil pan/gasket
AEM Cold Air Intake w/throttle body spacer
Borla Cat-Back Exhaust
Brown Dog MML
Body Lift 1.25
OME 2.5 lift
A new radio w/various upgraded speakers
Xenon flat fenders
Other stuff I'm sure

 

[Chris]

Fantastic looking Rubicon. I like the build idea too. Keep it simple and sweet. These things look great without much done to them.

 

[sq8810]

Dents and/or rust got the better of the front end. Fenders pre-drilled are 81$ on eBay btw! (from china but still)

 

[sq8810]

Front end work

 

[sq8810]

Front end mostly put back together

 

[sq8810]

Side view w/front end lifted only

 

[sq8810]

Now onto the rear end

 

[sq8810]

All put back together. Now for some paint and bigger tires (not too big though, 33's).

 

[sq8810]

Fantastic looking Rubicon. I like the build idea too. Keep it simple and sweet. These things look great without much done to them.

Thank you sir, I completely agree. The idea is for this jeep to be around for a very long time so I don't foresee any hardcore wheeling or the necessary mods to do so in it's future.

 

[Chris]

Thank you sir, I completely agree. The idea is for this jeep to be around for a very long time so I don't foresee any hardcore wheeling or the necessary mods to do so in it's future.

Yep, that's how I would do my next one. Start off with a clean Rubicon, do a 2.5" lift, 31s or 32s, a re-gear, some new bumpers, a winch, and that's about it.

I got way too carried away on my last one... to the tune of close to 60k.

 

[sq8810]

Yep, that's how I would do my next one. Start off with a clean Rubicon, do a 2.5" lift, 31s or 32s, a re-gear, some new bumpers, a winch, and that's about it.

I got way too carried away on my last one... to the tune of close to 60k.

It is definitely an addiction!

 

[sq8810]

Update: installed a bumper, fog lights, underside prepped/painted and body painted.

 

[Chris]

Damn? Is it all painted and everything? That looks absolutely awesome. Job well done my friend!

 

[DetroitTJ]

Jeep looks great.

I grew up in Saco! We moved away in 1993 when I was 15 years old. I went to Thornton Academy for freshman year of highschool. Just glad to see someone from Saco.

 

[sq8810]

...So my rear end blew up in Delaware on my way home from the OBX to ME. I think I had a pinion bearing go severely bad but I managed to limp it home 300 plus miles. Ordered a Dana 44 from Reliable Auto Parts in Yuma, Arizona and swapped the old axle (250K miles) with the newer one (100k miles). They let me keep my old axle which I was able to sell for 600$ to offset my costs. I called around for various quotes on rebuilding what I had, not knowing the extent of my damage and the costs pretty much came out the same.

3 hours to rip out and 4 hours to put in...also took the opportunity to install stiffer rear coils after recently installing a swing out tire carrier, hardtop and roof rack/basket. I've become really interested in overlanding recently but mostly want to be able to camp comfortably with the old jeep. The ride is back to what it used to be and I can actually drive it again without banshee noises coming from the rear!

 

[Mr. Pink]

looks like a solid start for sure.

 

[sq8810]

Recently hit 250,000 miles on the original (and very tired) motor. I was able to pick up a fresher motor (150k) for 600$. Some descaling, paint and all new gaskets from oil pan up and the fresher motor is ready to go in. I'd like to rebuild the original to a 4.6 and swap back in. Not a fan of the yellow, was going for more of a darker yellow to match the motor mounts/shocks...it'll work for now.

 

[sq8810]

Ended up rebuilding the original engine to a 4.6 stroker. Have about 1500 miles on it now, noticeable difference for sure, but nothing mind blowing. It ran horrible until I brought it a tuner...

That being said I have never messed around with building/rebuilding engines before, what a rabbit hole. Install took me a couple tries to get it right. First install sent a small amount of material from inside the timing chain cover through the oil galleys due to using the incorrect sized bolt securing oil pan to timing chain cover. Second try got sloppy and had a bearing clearance issue. Third try I had learned my lesson, took my time and did it right. Not a job for the faint of heart.

Engine:
9.6:1 compression (static) low 8:1 (dynamic)
0.020 decked
.030 over pistons w/-21cc relief
206/212 cam .450 lift
24lb/hr injectors
borla headers
high volume oil pump
high flow water cooler
other stuff...

You can see where the wear in the bearing is isolated to the middle near the oil galley, this is where the debris from the first attempt got bunged up.

My original cylinder head was cracked...I had to use the head from the second motor I picked up.