EJD's '00 TJ Sahara Overland Build & Excursions

EJD

TJ Overlander
Supporting Member
Ride of the Month Winner
Joined
Jul 16, 2016
Messages
1,965
Location
Oregon Coast
Ok wow, as I approach my 2 year anniversary of being a TJ owner I can't believe i'm here in the build thread section but it has been something I wish I did from the start but didn't. I had so many things going on and honestly never thought I would be in a position to truly be building a TJ but as time past, sure enough I have been building a pretty awesome low-lift overland daily driver.

I will do my best to rewind a bit and post up pictures and links of anything relevant to my timeline and hopefully most of you will get the idea and can piece together the rest. Enjoy!

This was the day I got my first Jeep, a Forest Green 2000 Jeep Wrangler TJ Sahara.
https://wranglertjforum.com/threads/new-member-first-jeep.1950/
Build 01.jpg
Completely bone stock at this stage, and 148k on the clock.

I got my Jeep as a result of a car accident and the totaling of my previous vehicle a month prior. The Jeep was an even buy from what my insurance check was for my totaled vehicle. I didn't know anything about TJ's at all except that its what I wanted...and what people in my family have been telling me to get for years.

Anyway it was a road trip to get it and get it back home (which was coastal FL at the time), I could not wait to rip the doors and top off when I got home! From this day on, I knew...this was it for me.
Build 03.jpg

I quickly realized that I needed something to help with all the sun. I stumbled upon SPIDERWEBSHADE!
Build 04.jpg

I then quickly realized that I needed something to help with all the rain. I went with the Bestop Trail Cover!
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Now my commute to work at the hospital was only 5 miles each way, so I was not racking up many miles each day. The beach was only a mile away so I hit the coast up every chance I got and I totally fell in love with this thing. I installed a 12" Kicker Comp in the back and deleted the rear seat for my dog to ride in.

The first thing that actually failed on me was my brake line burst leaving my driveway one day. Luckily it was not in a much worse scenario. I would recommend people do visual inspections of them up front especially. This was a front passenger side brake line and it was my first task on my new Jeep. I went with the Rugged Ridge full brake line set and had it installed in a day. Also broke a bleeding valve and replaced both of my rear drum cylinders while I was in there.
https://wranglertjforum.com/threads/lost-my-brakes.2630/
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Next I decided to have some fun and get a few more toys as I was making some good money and wanted to get a few things to dress it up a little. I went with the GraBar and BootBar set as I was going to be running topless and doorless 9 months out of the year.
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Next I got a really good deal on these Drake Offroad TJ Grill Inserts, I loved the idea of cleanly covering up the front a little and keeping out all the crazy flying bugs in FL during that season.
Build 02.jpg

Next...tires! I had to save up a bit for a 5-pack of 31" BFG KO2's but it was so worth it.
Build 09.jpg

I then had to take them for a test run. Wet sandy trails to palmetto forest...I had a riot.
Build 10.jpg Pro 02.jpg

I performed a "Tub Rail Armor" mod with a bedliner.
https://wranglertjforum.com/threads/tub-rail-armor.2051/
Build 12.jpg

Upgraded my Jeep decals in custom distressed desert tan to match my hardtop and spiderwebshade.
https://wranglertjforum.com/threads/jeep-decals.2230/
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Prepping for our 1st hurricane to hit, I bought a Rampage Brush Guard thinking it may help with potential debris...and on the overgrown FL trails.
https://wranglertjforum.com/threads/hurricane-approaching.2329/
Build 16.jpg

Upgraded to Sunpie LED head lights, and picked up a set of KC LED tail lights.
Build 17.jpg

Me just loving my Jeep!
Build 21.jpg


Added a VDP Overhead Organizer and Bestop HighRock Tube Doors!
https://wranglertjforum.com/threads/hard-top-off-tube-doors-on.3442/
Build 22.jpg

Next chapter, I have a major stalling issue. I started with all the obvious and it ended up being something none expected...the Power Brake Booster. I'll try to give you the cliff notes here...I replaced the IAC Valve, TPS, MAP, CPS, CMP and all 4 O2 sensors. I dropped the gas tank and replaced the whole Fuel Pump Assembly, and finally the Brake Booster was the vacuum leak that was causing my stalls.
https://wranglertjforum.com/threads/reverse-to-drive-sputter-stall.2784/
https://wranglertjforum.com/threads/help-needed-with-mysterious-stalling-issue.4348/
https://wranglertjforum.com/threads/jeep-died-while-driving-tonight.4087/
https://wranglertjforum.com/threads/o2-sensor-identification-clarification.4056/
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Also resolved a serious shifting issue I was having by learning how to properly check the ATF. This was a game changer for me. Thank you @Jerry Bransford!

Next I was location hunting for a photo shoot for this amazing picture!
Build 25.jpg


Which was really the location for our Baby Announcement Picture!
https://wranglertjforum.com/threads/our-baby-announcement-photo.5275/
Build 26.jpg

Next I would tackle the custom Yakima Roof Rack job. This was something I wanted to do as preparation for a 2-part cross country relocation. FL to NY, then NY to WA. 2nd pic there is of me on the road headed north.
https://wranglertjforum.com/threads/yakima-roof-rack-setup-on-tj-hardtop.7106/
Build 27.jpg Build 28.jpg

Installed my Smoked Turn Signal kit and shined the Jeep up really nice for a beautiful summer day.
Build 29.jpg

While troubleshooting this little leak, I replaced the upper and lower radiator hoses, installed a fresh water pump, thermostat, new belt and did a reverse back flush of the heater core.
Build 30.jpg

There are just too many pictures for tho but I underwent a major frame repair. Replaced frame sections with Safe-T-Caps including the rear trail arm all the way up to the front. Both sides. Huge job, but its all good now...
https://wranglertjforum.com/threads/going-in-for-frame-repair-surgery-today.7373/
Build 31.jpg

Now, new Odyssey 34-PC1500T Battery and Mil-Spec Terminal upgrade.
https://wranglertjforum.com/threads/battery-terminals.7779/
Build 32.jpg

New suspension upgrades! H&R 1" Raised Springs and Rancho RS5000X Shocks. Also installed new jounce bumpers and cups too! Sitting a little nicer, and definitely riding better now.
https://wranglertjforum.com/threads/stock-spring-inquiry.6295/
https://wranglertjforum.com/threads/2-surprises-outside-my-door-today.7626/
https://wranglertjforum.com/threads/rusty-jounce-cup-bolt-removal-help.7847/
Build 33.jpg Build 34.jpg

During a few late nights working on my Jeep I realized that my under hood light (that I deleted a long time ago cause it was toasted) needed an upgrade and I had 2 KC Cyclones laying around from my last vehicle. I installed them right up the center of the hood and mounted the switch right on the fuse box bracket.
Build 35.jpg Build 36.jpg Build 37.jpg

And that brings me to leaving the east coast and arriving in the wet and foggy pacific northwest.
Build 38.jpg


My TJ now has 161k on the clock. So 12k miles in 2 years on a DD with a complete cross-country journey isn't too bad! I did not run into any issues on any of my road trips or outings thankfully, I think its due to preventative maintenance and the help of THIS forum and its members of course. So @Chris thanks again man for starting forum and making/keeping it awesome, it has helped me tremendously and taught me so many things. Obviously many people contributed to helping me and there are just so many of you to thank, that I will just say Thank You! and hope that you know who you are!

I look forward to learning a lot more here, building up my TJ a bit more, and being a Jeeper for life.
 
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About time you had a build thread @EJD, and a nice thorough one at that! That hunting photo shoot photo looks really, really good. That's definitely a classic.

I've lived in the PNW all my life, and it's a great place to live, that's for sure. We don't have to deal with salted roads or rust here, which is another major benefit. Not to mention our climate is really tolerable.
 
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Congrats! Great write up. And welcome to the PNW. Work bring you over here?
Thank you! And yes, work and play.
About time you had a build thread @EJD, and a nice thorough one at that! That hunting photo shoot photo looks really, really good. That's definitely a classic.

I've lived in the PNW all my life, and it's a great place to live, that's for sure. We don't have to deal with salted roads or rust here, which is another major benefit. Not to mention our climate is really tolerable.
Haha, ikr. Long time coming. I have a huge love for the PNW, my wife and I got married in Oceanside, OR (Tillamook) and it has always been a home away from home for us. (There's just no work in that town, or we would be there). I love how rugged the west coast is in comparison to the east. Plus i'm a Goonie at heart.
Your build mirrors aspects of mine. Like where you are going with it so far. Welcome to the left coast!
Thank you! I hope at some point I can get in on a meetup with all you guys now. You have some killer locations down there, and i'm dying to hit up the Redwoods NP.
 
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ZJ Tie Rod Conversion time!
I have had this project on hold due to weather but today was beautiful outside and figured I would put some work in and see what happens.
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Been soaking these bad boys in Liquid Wrench for the past week and they came right off no problem. Only thing was I had to remove my wheels, there was just no way to remove the cotter pins without doing so. No biggie. Man that Castle Nut doesn't look good though!
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As it sits now i've got both Outer Tie Rod Ends out, have the Steering Stabilizer out, and I cannot for the life of me get the damn Drag Link out of the Pitman Arm. Lol.
IMG_7319.JPG

I tried the BFH by itself and it just isn't happening. I have no pickle fork or tie rod puller so thats gonna be the next thing I try. I just have to shoot over to one of the auto store nearby and see if I can rent one for a few.

But yeah, fun stuff!
 
Ok, back on track now, it took a little more persuasion if you know what I mean.
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All measured up ready to go back on. (Thanks guys for the tips). That Drag Link @ Pitman Arm kicked my ass.
 
Alright, beautiful day here today so I was able to complete the ZJ Tie Rod Conversion and finished it off with a DIY alignment right in the driveway.
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Took it for a test drive and it feels pretty good! Thanks @Serbonze for all your assistance in answering my 20 questions.
 
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Also got a really good deal on these Rugged Ridge Diff Skid Plates for my Dana 30 & Dana 35. They go for $100/ea and I landed them for $25/ea.
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I had the rear one on for about a year now but the front one just went on sale and I had to scoop it up.
 
I ordered up a matching set of EAG Classic TJ Bumpers w/ Winch Plate. I liked these because they were stock-like with some updates. Beefier steel, more coverage, better lines, approach angles, and recovery points. Plus the hitch receiver in the back and winch mount up front will add significant versatility to my setup. These bumpers also came with 4 3/4" D Rings with rubber isolators.

$300 for the set, so pretty affordable all things considering, plus my front bumper arrived with some paint scuffed off during shipping on one edge, and EAG credited me back $100 for the inconvenience. They also offered to take them back and send out a new set free of charge too. I opted for the money back as they are going on a Jeep and things will get scuffed up anyway. So that made it an even sweeter deal at $200!

Here they are so far:
EAG Bumpers.jpg
 
Sweet deal! I like the simple, clean look of those.
Ikr! I didn't want to stray too far from stock but there are some good features on these guys for sure. Plus i'm always on the lookout for a good deal. Only thing it doesn't have are holes for a license plate.

Now to figure out mounting up the winch. (Have never done so before).
Good Stuff @EJD! That's a good looking TJ.
Thanks man, it's coming along thats for sure. Trying to keep the low-lift TJ's alive and well!
 
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ZJ Tie Rod Conversion time!
I have had this project on hold due to weather but today was beautiful outside and figured I would put some work in and see what happens.
View attachment 33513



Been soaking these bad boys in Liquid Wrench for the past week and they came right off no problem. Only thing was I had to remove my wheels, there was just no way to remove the cotter pins without doing so. No biggie. Man that Castle Nut doesn't look good though!
View attachment 33505



As it sits now i've got both Outer Tie Rod Ends out, have the Steering Stabilizer out, and I cannot for the life of me get the damn Drag Link out of the Pitman Arm. Lol.
View attachment 33506
I tried the BFH by itself and it just isn't happening. I have no pickle fork or tie rod puller so thats gonna be the next thing I try. I just have to shoot over to one of the auto store nearby and see if I can rent one for a few.

But yeah, fun stuff!
Do you remember the part numbers? I have already got the
Moog DS1312 tie rod
Moog ES3096L tie rod end
Moog ES2079S tie rod adjusting sleeve
I wass just going to reuse the old drag link but it’s got way to much play on it. So drag link Moog #? Do I need another sleeve ?
 
Do you remember the part numbers? I have already got the
Moog DS1312 tie rod
Moog ES3096L tie rod end
Moog ES2079S tie rod adjusting sleeve
I wass just going to reuse the old drag link but it’s got way to much play on it. So drag link Moog #? Do I need another sleeve ?
That would be DS1430 my friend. Found here: https://www.amazon.com/gp/product/B000C5406S/?tag=wranglerorg-20 And actually its at a decent price too at the moment, I would scoop that up and if you can just get another sleeve (makes life a little easier, and they're not that expensive).

Also, here is a whole thread on the ZJ Tie Rod Conversion too if you haven't checked it out. https://wranglertjforum.com/threads/zj-tie-rod-conversion.2183/page-2#post-146431
 
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Ikr! I didn't want to stray too far from stock but there are some good features on these guys for sure. Plus i'm always on the lookout for a good deal. Only thing it doesn't have are holes for a license plate.

Now to figure out mounting up the winch. (Have never done so before).

You can make a simple license plate holder once you get a winch installed. 2 Maglight holder clips, a piece of aluminum/metal, some rivets, and bam!
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You can make a simple license plate holder once you get a winch installed. 2 Maglight holder clips, a piece of aluminum/metal, some rivets, and bam!
View attachment 35077
View attachment 35078
View attachment 35079
I don't have a roller fairlead, though i'm sure there's a way to adapt it to a hawse. Looks cool though I was already trying to think of options for this. I was hoping to find such a bracket that might let me mount my 10" KC Flex Array on there along with a license plate mount. As long as it doesn't come across as overkill, just trying to fit my toys on there and be legal.
 
Yeah, if you went into the ZJ Tie Rod thread I linked earlier, you would see that in a nut shell, the Crown kit sucks in comparison and is of much lower quality.
 
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