Frame Swap

RonC

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Nov 20, 2023
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Massachusetts
I have been in the middle of a frame swap on my 2000 Tj , I made the mistake of buying a 03-06 frame and now I’m trying to figure out my issue with the steering gear box. I cannot weld so I’m trying to find another solution. I was thinking about buying a 03-06 gearbox and just replacing the lines and the linkage to make this work , or if there is a conversion kit I can buy to solve my issue.
 
Welcome to the forum as well!!!

have you addressed the skid plate differences already?
 
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Similar to what I ended up doing. I cut off the sleeves on the old frame and welded them onto the new frame. I seem to recall it being about half a hole different.

I don't recall any issues with the skid but maybe I just used the newer skid plate.

Maybe I am incorrect but I recall the 03 transmission skid plate (the large one) being different than the 02 older.
 
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I just don’t know how to weld , I’m just trying to find an easier solution . I found this https://www.vividracing.com/jeep-st...inaw-conversion-agr-steering-p-151908087.html and I wasn’t sure if this would solve my issue?

I dont think that will work as you will still be left with the incorrect mounting pattern? Unless I'm not understanding what they are selling correctly

@mrblaine certainly you have run into this?

I think I would buy a used Mercedes box and adapt to the pump as needed and call it a day. You will probably need to swap the steering shafts as well
 
I dont think that will work as you will still be left with the incorrect mounting pattern? Unless I'm not understanding what they are selling correctly

@mrblaine certainly you have run into this?

I think I would buy a used Mercedes box and adapt to the pump as needed and call it a day. You will probably need to swap the steering shafts as well

The only reason I thought this would work because it’s the mounting pattern for the 03-06 frame that I have but it says that I need the 2000 style linkage and lines , so I am honestly confused .
 
You're better off keeping your 97 - 02 steering box. There are more options for replacement, if that becomes a need. That said, there are mobile welding services that will come to your home. If you do the prep work, all they'd need to do is a quick weld. Seems like the cost of that would be reasonable and save you a lot of aggravation.
 
I did the same thing-replaced my '98 frame with an '06. I went with the ZF steering box from the '06-a much easier solution. A few things are different: power steering lines are longer and shaped differently. They are also in the way when you go to put the body back on the frame-I reconnected mine after the body was bolted. The lower steering rod on the '03-'06 (between the steering box and the rod that connects to the steering column) is longer by about 1 5/8". You will need the one from an '03-'06. Also, it will sit just a bit lower and you may want to add a 3/8" spacer to the bottom of the steering rod bushing bracket. You will also need the transmission mount from an '04-'06 to connect to the skid plate.
 
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I have been in the middle of a frame swap on my 2000 Tj , I made the mistake of buying a 03-06 frame and now I’m trying to figure out my issue with the steering gear box. I cannot weld so I’m trying to find another solution. I was thinking about buying a 03-06 gearbox and just replacing the lines and the linkage to make this work , or if there is a conversion kit I can buy to solve my issue.
You can use the 03-06 steering gear with no issues and just use the 03-06 pressure hose and return line to hook it up to the 00 pump and reservoir. Barring that, you can use one of the conversion gears done on the Saginaw gear case.

Check and make sure AGR is still in business before you buy that one.
If you do the PSC, it needs the upgraded pump and reservoir or you'll wear it out much faster than is prudent.
 
If you do the PSC, it needs the upgraded pump and reservoir or you'll wear it out much faster than is prudent.

I've been running the PSC gear in my '05 for maybe 2 years with the original pump. Tires are 315/75r16, not huge.

Are you saying my PSC box days are numbered? Sounds like maybe I should upgrade. Which pump should I be using?
 
I've been running the PSC gear in my '05 for maybe 2 years with the original pump. Tires are 315/75r16, not huge.

Are you saying my PSC box days are numbered? Sounds like maybe I should upgrade. Which pump should I be using?

I don't know which gear you have.
 
I did the same thing-replaced my '98 frame with an '06. I went with the ZF steering box from the '06-a much easier solution. A few things are different: power steering lines are longer and shaped differently. They are also in the way when you go to put the body back on the frame-I reconnected mine after the body was bolted. The lower steering rod on the '03-'06 (between the steering box and the rod that connects to the steering column) is longer by about 1 5/8". You will need the one from an '03-'06. Also, it will sit just a bit lower and you may want to add a 3/8" spacer to the bottom of the steering rod bushing bracket. You will also need the transmission mount from an '04-'06 to connect to the skid plate.

Would I just need the 03-06 transmission mount or do I need the 03-06 skid plate as well. Would I not be able to use my 97-02 one?
 
Would I just need the 03-06 transmission mount or do I need the 03-06 skid plate as well. Would I not be able to use my 97-02 one?

97-02 and 03-06 skids are different as to their attachment to the frame, mounting location, and bolt types. 03-06 went from SAE to metric bolts. The 03-06 frame angles are different from 97-02 and you will not be able to get them to line up. You will definitely want the 03-06 skid plate and the trans mount.
 
I have the version with ram ports that fits an '05. Is there more than 1 fitting that criteria?

There are several but only if ordered by someone like me. If the t-bar is the standard offering, then you should be running the standard higher volume, higher pressure pump with the remote reservoir.
 
There are several but only if ordered by someone like me. If the t-bar is the standard offering, then you should be running the standard higher volume, higher pressure pump with the remote reservoir.


Looking at PSC's web site, it's not totally clear which pump you're referring to. And I also don't know exactly what I need for setting it up with the remote reservoir and such. Maybe I should give you a call. Does BMB maybe have a kit for such an upgrade? Or should I go with 1 of these:
https://www.pscmotorsports.com/all-...-2006-tj/2003-06-tj-40l/xd-steering-pump-kits