2006 LJ Rubicon - First Jeep Build - Even an idiot can do it

[Hackyman]

Full disclosure - I have no idea what I'm doing, never owned a jeep, only worked on my Toyota's, I'm a shit mechanic.

Recently purchased (well February 2024) a 2006 Wrangler LJ Rubicon, with 155k miles. Jeep was completely rust free, appears to never been offroad. Guy I bought from said he put it in 4WD on occasion to get up a grassy hill on his property. He told me he avoided ever driving it in the winter in the mountains, so frame appears very clean. Jeep came completely stock, with street ties in near original size, lockers work front and rear. Paid $15k, been wanting one of these for 15 years, saw it pop up while looking for something else on craigslist, and bought it.

The good:
Rust free
Rubicon
Not abused offroad

The bad:
I hate black vehicles
There is a intermittent transmission issue I am trying to work out
Leaks oil
Paint is checked and clearcoat is peeling on the hood
Top corners of tailgate slightly bent

Build Plan
35 inch tires - Thinking Nitto Trail Graplers in 35x11.5 on some set of 17" wheels
5.38 gears - replace air lockers with Eaton e-lockers while doing gears
Currie/Savvy 4" short arm lift - sitting in closet
Savvy Tummytuck - Sitting in closet
Big Brakes from BMB - need to figure out if I will need to do manual hubs before buying - though was hoping to make a black friday purchase from the Wizard. Will also impact wheels

As purchased - installing Black Magic Brakes body lift, with Doorman replacement rubber body mounts. Mr. Blaine was kind enough to explain which two part numbers to buy for the body mounts over email.

All the body mount bolts came right out without drama, as has every bolt I've touched. Very happy to have a rust free start.

 

[Hackyman]

Post Body Lift:

 

[Hackyman]

Mr. Blaine was kind enough to braze a bund into a Doorman pan I mailed him, and answer my stupid questions when I didn't understand that the sensor/bung was tapered. Sealed with Loctite 592 sealant. Replaced transmission gasket with lubelocker, and put a new filter in while I was in there. No leaks.

Trying to figure out things for myself and bug him less. He's too helpful.

Installed Transmission Temp Gauge:

I thought I was being overly clever by installing this digital gauge, vs the jeep branded autometer gauge. The dim function just makes the LEDs flicker, may be able to fix with some sort of capacitor, but not sure. Oh well, it works on full dash brightness.

Used positaps (love them) to wire the gauge in, ran wires out the drivers side existing wiring hole in firewall, and over the top of firewall, down to the transmission. Had to extend the wires a bit. All splices and terminals were crimped with copper crimps, and shrinktube.

A nice 80 degree day.

 

[Hackyman]

Put the jeep in the garage and started some disassembly to do something about the color. Debated painting, but cost was high, so trying out a wrap. Never done one before, don't know anyone who has, but giving it a try.

Took the fenders, bumpers, mirrors, stock "sliders", taillights, and tire carrier off.

Experimented with some random wrap color samples, and settled on this blue. After I bought 25 feet of it, I'm not sure I like it, but its too late so its going on. Total cost of the materials was ~$250 for Avery wrap, plus another 50 bucks or so in tools.

Grill off to wrap, and install Setrab transmission cooler.

Grill complete

Also did the toyota headlight mod. What a deal at <$20 for two housing, a crap load of wiring/relays, and 100 nice zipties. Lighting is better than my tundra halogens, and will still upgrade to 100w bulbs. I dont like the look of LED lights on the older jeeps.

 

[Hackyman]

Wrapped the front fenders.

In progress:

Complete, with Setrab, and garage stools borrowed from our dining room table:

 

[Hackyman]

With the help of Mr. Blaine's write up on the Setrab, I had a friend weld some bar stock onto the v brace, and purchased the appropriate fittings from Mr. Blaine, as well a little custom stainless tube that makes getting the passenger side fitting out of the grill a piece of cake.

For some reason when welding, all this liquid (not water, seemed like oil), kept coming out of the v-brace. Not sure where it came from - reminder to change your v-brace oil.

Hoping its welded low enough that should I need to go hydro assist, that Mr. Blaine's kit will fit.

 

[Hackyman]

Removed the oil pan to fix the non-stop oil leak. 4 or 5 of the oil pan bolts were finger tight. Just tightening them may have solved my problem, but was in there so put a felpro gasket in. Was concerned it was a RMS leak, but flex plate was dry, so I took my chances. After fix, no more leaks after a couple hundred miles of driving.

 

[Hackyman]

Looking at wheels:

Anybody have any suggestions for 17" options with proper backspace?

If I do the small WU-07 hub conversion, I'd probably go with the method 305NVs with 4.75 BS. I believe the hub kits widens the front track by roughly 3/4".

If I do the big hub kit (WU-08), I have no idea what wheels will work. Not seeing anything that isn't nasty looking.

If I don't have any vibes, maybe I will spring for some trail ready bead locks with my savings from not doing the hub kit.

 

[Hackyman]

A mouse had obviously enjoyed its stay in the 4.0. Had been busy eating the injector wires.

Cut the mangled wire out, and recrimped new terminals, wrapped it in some nylon loom.

The connector can be purchased with pre-crimped wires from MOPAR - if available - part number 05161919AB or you can purchase the terminals and connector loose here for 1/4 the price, and crimp yourself. https://www.corsa-technic.com/item.php?item_id=2028

No affiliation, they have just been extremely helpful on past projects. I sent a picture of the connector, they figured out what it was, and added it to the website.

 

[Hackyman]

After it appeared to be working, I took it for a spin up to a fire lookout near my house. Saw a couple other jeeps when I was up there. Ready for new suspension after all the thrashing around on those rocks.

 

[Hackyman]

Blank

 

[Hackyman]

Pulled the axle out to start rebuilding. Passenger side had an offset ball joint on the upper joint. Not sure why. Cut out a little brace for the upper control arm mount. Never used an angle grinder or welder before yesterday, maybe a couple times as a 15 year old, so forgive the shitty welds. I think it will be strong enough for its purpose.

Question on my plan for brakes- the existing brakes are shot. Plan is to replace with a BMB big brake kit. Before ordering brakes, i need to find out if ill need manual hubs. In order to test to see if I'll need hubs, I'd need to at least buy new rotors and pads to make it drivable, which will end up just being thrown away in the end.

Beyond trashing brake parts, is there any risk of damaging new ball joints when swapping the knuckles?