EJD's '00 TJ Sahara Overland Build & Excursions

Added the Yakima SlimShady RTA to the roof rack setup!
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Picked up a Barnes 4WD Fairlead LED Mount, and integrated it into my KC Flex Array.

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Switched over to the Yakima LoadWarrior+Extension today as well. The paint was totally sun-baked from the life in the Endless Summer, so I gave it a couple nice coats of truck bed coating and it brought it right back to life again.

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New Yakima Timberline Towers & Roof-less Rack Setup.

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Should also have a few of those Axe & Shovel mounts for the sides of the basket on soon too. Adding the RTA back into the fold for a few and will have this thing loaded out in no time.
 
You’re Jeep is really starting to grow on me.
 
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You’re Jeep is really starting to grow on me.
Oh me too man! I just love how customizable these things are, how many different configurations I can have, and how many looks I can have. I've lived in every time zone, north and south, east and west, and this thing can adapt to just about any terrain I encounter.

I'de love to throw a nice RTT up there next, we'll see if Yakima wants to back me on that one too!
 
Oh me too man! I just love how customizable these things are, how many different configurations I can have, and how many looks I can have. I've lived in every time zone, north and south, east and west, and this thing can adapt to just about any terrain I encounter.

I'de love to throw a nice RTT up there next, we'll see if Yakima wants to back me on that one too!
I love the customization factor as well. You’re building a great all around rig. Keep it up! I’m tuned in.
 
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Uncle Bill 1944.jpg
My TJ now has 161k on the clock. So 12k miles in 2 years on a DD
lol, I bought mine with 90K 7 years later it has 240K and I add 24K every year. I put in a reman engine last year so I figure its good till I hit 80. Might tear it apart for a full repaint on my 70th.

You look younger than my grandson. Keep that TJ, my first vehicle was an M38 straight out of high school 45 years ago. SO wish I had resisted the 1970 455HD Trans Am pull and kept it.

Heres a pic of my Uncle Bill in 1944 with his government issued Jeep, back when all Jeeps were government issued.
 
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Just found this thread but this is my kinda TJ !! I went with HighLine instead of low lift. 33s on a stock TJR.
Haha, I could have seen myself going that route too! I catch glimpses of yours from time to time and I always think it looks great.
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lol, I bought mine with 90K 7 years later it has 240K and I add 24K every year. I put in a reman engine last year so I figure its good till I hit 80. Might tear it apart for a full repaint on my 70th.

You look younger than my grandson. Keep that TJ, my first vehicle was an M38 straight out of high school 45 years ago. SO wish I had resisted the 1970 455HD Trans Am pull and kept it.

Heres a pic of my Uncle Bill in 1944 with his government issued Jeep, back when all Jeeps were government issued.
Classic picture! Love some of those old time photos, i've got a good one of my Grandpa from way back and its sort of the same.
BTW, can I ask where you got your reman 4.0? Might be needing one very soon...due to a recent unexpected turn of events this past week...
 
S and J Engines, Spokane, WA. They ship all over the world.

https://www.sandjengines.com
Well good thing spokane is only a couple hour drive for me too, depending on what shipping costs, thanks for the link.

Okay, so where's the story behind that statement? Been waiting patiently......;)
Oh I started this too https://wranglertjforum.com/threads/best-guide-for-4-0-repair-rebuild.14681/#post-235309

Yeah it was a nice extended weekend of overlanding here on the divide with my dad that for some reason or another ended with mechanical failure on the way home...had to get towed over 100 miles once this happened as to not further the damage and save the engine from being completely ruined. Put a damper on things but i'm trying to stay positive by thinking it could have been much worse, and hopefully with the help from some friends both here and there, I may be able to get this thing fixed for minimal costs and learn a bunch about my TJ and engine in the process.

As it sits now in my garage, the understanding is that there is a blown/thrown rod on the bottom end, and with the engine running there is a significant knocking sound. There is no visible damage anywhere, nothing broke through or cracked that we can see, and there is no smoke or leaks currently either. I'll obviously keep this thing updated with pictures for anyone interested in following the progress or to see what actually failed inside the 4.0 at the time.
 
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Well good thing spokane is only a couple hour drive for me too, depending on what shipping costs, thanks for the link.


Oh I started this too https://wranglertjforum.com/threads/best-guide-for-4-0-repair-rebuild.14681/#post-235309

Yeah it was a nice extended weekend of overlanding here on the divide with my dad that for some reason or another ended with mechanical failure on the way home...had to get towed over 100 miles once this happened as to not further the damage and save the engine from being completely ruined. Put a damper on things but i'm trying to stay positive by thinking it could have been much worse, and hopefully with the help from some friends both here and there, I may be able to get this thing fixed for minimal costs and learn a bunch about my TJ and engine in the process.

As it sits now in my garage, the understanding is that there is a blown/thrown rod on the bottom end, and with the engine running there is a significant knocking sound. There is no visible damage anywhere, nothing broke through or cracked that we can see, and there is no smoke or leaks currently either. I'll obviously keep this thing updated with pictures for anyone interested in following the progress or to see what actually failed inside the 4.0 at the time.
Sounds like a bad rod or main bearing, by your description. If you had actually "thrown a rod", you'd know it for certain. There just isn't anything quite like that sound, or the resulting damage! :eek:
 
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/
View attachment 33383 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.
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I quickly realized that I needed something to help with all the sun. I stumbled upon SPIDERWEBSHADE!
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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.
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Next...tires! I had to save up a bit for a 5-pack of 31" BFG KO2's but it was so worth it.
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I then had to take them for a test run. Wet sandy trails to palmetto forest...I had a riot.
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I performed a "Tub Rail Armor" mod with a bedliner.
https://wranglertjforum.com/threads/tub-rail-armor.2051/
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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/
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Upgraded to Sunpie LED head lights, and picked up a set of KC LED tail lights.
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Me just loving my Jeep!
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Added a VDP Overhead Organizer and Bestop HighRock Tube Doors!
https://wranglertjforum.com/threads/hard-top-off-tube-doors-on.3442/
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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!View attachment 33423

Which was really the location for our Baby Announcement Picture!
https://wranglertjforum.com/threads/our-baby-announcement-photo.5275/
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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/
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Installed my Smoked Turn Signal kit and shined the Jeep up really nice for a beautiful summer day.
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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.
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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/
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Now, new Odyssey 34-PC1500T Battery and Mil-Spec Terminal upgrade.
https://wranglertjforum.com/threads/battery-terminals.7779/
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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/
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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.
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And that brings me to leaving the east coast and arriving in the wet and foggy pacific northwest.
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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.
Can you fit a winch under the brushguard? I love the look and was thinking of buying the same one for my Sahara.
 
Can you fit a winch under the brushguard? I love the look and was thinking of buying the same one for my Sahara.
Well thanks!
Yes you can fit a winch in there (but you have to do a small chop in the brush guard), check out page 2!
 
Nice build man, giving me lots of ideas of what I might do. Really like the front light upgrade and front bumper. What style is it do you know?
 
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