My 99 TJ build

Redsquatch

Member
Original poster
Supporting Member
Joined
Aug 7, 2025
Messages
73
Location
Vancouver, Washington
So i finally bought my first TJ just about 2 years ago, I've been looking at them off and on for a years now i finally decided to pick one up, and i can say its been one of the most fun projects/vehicles I've ever owned.

Its not a rubicon its only a 99, the previous owner put that on it and its so sun faded and baked on it only wants to come off in tiny pieces

Here is the Day I brought it home, note the "Warn" winch, turns out its a smittybuilt XRC10 someone was ashamed of lol.
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After a week of driving my new Jeep around it started making a clicking sound when i would turn, i ended up pulling the diff cover to find the spider gears were missing teeth, i chocked it up to Dana 35 problems and replaced them, also threw in a set of new LSD clutches while i had it apart.


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Started finding Mismatched hardware the wasn't even tight, this became a common theme with this jeep haha.
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3 Weeks later its going out for its first trip, jeep did great didnt miss a beat, but it sure felt gutless with 3.73 gears. My buddies 2001

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Getting lights Hooked up, Really applied lights before lockers here haha.
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Trans temp gauge.
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Now its locker time! love these cheap little guys, i had them in my XJ for years and never had an issue with them, i decided that i wanted a selectable locker for the rear, i didn't like how the Spartan would unload sometimes in my Xj and wanted to not hear the loud bang when it unloads, but the front was never noticeable outside of being in 4 wheel
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Installed in the carrier and back in the housing.
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Added some tie in brackets for the rear bumper.
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Out again for another trip, this is the only picture i took, I was having too much fun trying out the new locker.
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Got started on the Slip yoke eliminator the following weekend, went with a rough country SYE and Adams drive shaft
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Scored some seats with brackets from an 05, nice to have the fold and tumble feature on the drivers now. plus the old drivers seat foam was mostly gone so it was a well needed upgrade.
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Not sure why it has rock sliders and rocker armor, but i pulled them off to repaint them, thy were peeling and showing rust in areas so i figured why not, i want it to look nice.

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Pulled the drivers off and just about knocked myself out slapping my forehead lol. this must one of those snazzy multi position rocker armors. note the multiple holes. someone really didnt measure twice!
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Got them mounted back up, looks much better than flakey paint and rust
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Got a binkini top for it.
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Now for the fun stuff, i managed to score a rubi44 for 600 with new in box 4.56 gears and the locker pump.Jjust happens to be the ratio i wanted to go with having a 32RH and 35s.


Starting the tear down, going to build this and get all the part for the front ready for a regear so the jeep isnt down for a while waiting for things to arrive.
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Sadly i cant find the pictures of the gear patterns for the 44, so for now just imagine the sight of 4.56 gears and a Rubi locker. i did replace the wheel bearings too, i was already in there might well get it knocked out
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3D printed myself a new switch panel, i used ASA filament.

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More work on the 44 getting the brakes assembled. 4
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Managed to find one of these old net tops, i always thought they looked cool. f

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Got the 44 all buttoned up and read to install, parts arrived early for the Dana 30, so i tore into that, made some setup bearings and got to work setting up the 4.56s


Good thing i started this not sure how that bearing wasnt making noise, the other side was pretty worn but not that bad.
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Had a little accident, i dropped one of the carrier bearings and it exploded everywhere, my own fault. luckily the local parts store had the same brand in stock.
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Carrier reinstalled and axle reassembled, really need to get better at taking pictures, i just get so caught up on what I'm doing i forget i even have the phone.
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Pulling the Dana 35 for the 44 install.
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44 is in, install went alot faster than i expected it too.
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got everything hooked up and took it for a test drive. wow what a difference 4.56s make over 3.73.

I ended up mounting the locker pump under the drivers seat
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Well that was short lived, was testing the rear locker in some gravel, i heard it go pop and them it was back to being an open diff. barely made it 800 miles lol. This ended up breaking and was allowing it to free spin even when locked the toothed ring would free spin on the shaft ., so i guess its time for a new locker.

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Figured buy once cry one and went with an Eaton elocker.

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and its in back to breaking the gears in haha.
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installed a new carpet kit, the one it had was pretty hacked from someone trying to make it fit, pretty sure it wasn't for a TJ .

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Well the Jeep developed a off and on miss fire, started to checked things over, plugs and wires looks great so i pulled that cap to inspect it and wouldn't ya believe it was super corroded. Got that replaced with a new one from Accel
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About a week later, i took it up to Jones Creek a local ORV park to put the new elocker to the test
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Gas tanks got a nice big dent in it, and i smooshed my tip, Hate when that happens.
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Now for some fun stuff, got new core 4x4 arms, proper length shocks, and mini skids, and a hardware kit as every arm had different bolts in them.

The old shocks were beyond worn out, once i got them off and got a good look at them there was almost zero damping left in them, the parts numbers came back for a 2in lift.
What a difference that made, went from bouncy all over the road to a nice and tight ride that handles very well.
While i was in there i got some bump stops setup too. The original jounce ones were completely blown out. being cheap i used hockey pucks, did the same on my old Xj.

Also managed to get a set of extended brakes lines on sale
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Took it up into the hills a few weeks later to see how all the new parts work together, what a difference everything made. it actually articulates and rides smooth.
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Well, on the way home stopped for fuel and gave everything a quick check over. the wheel seal on my rebuilt 44 took a crap, oil all over the tire and in the wheel well. got that replaced pretty quick as i had a spare seal and bearing on hand
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Not too long after the wheel seal bit the dust, it started making a clunking noise from the front end. After some poking around i found that both front u-joints had a very slight amount of play in them, tearing everything back apart once again.
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Glad i caught it before i went out on the next trip, threw some new spicer joints in there and called it a day.
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Decided that im tired of looking at the generic chinese bumper, so i was browsing ebay and found a company making a stubby winch bumper here in the states, i also found a weld on stinger kit that i wanted to add on to it.
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Looking good so far.
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Al welded up and painted, I moved the winch solenoid for a cleaner look and moved the plug just next to the passenger side fog light, i also did the same with the air connection for my OBA.
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Repainted the shackles so they look a little less beat.
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Rear Main seal bit the dust, so spent some time on that last week and went out to browns camp for a buddies B-day wheeling trip.
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No more oil drips sure is nice.


Browns camp was a blast, I haven't been there in about 12 years. My buddies JK and his dads Landrover.
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Completed Section 4-1 of the WABDR. were weren't able to complete section 3 due to fallen trees, we cleared about a half mile of road before finding more trees and ultimately turned around to head back and make our way to section 2. All in all it was an amazing trip the jeep didn't miss a beat. Just super dusty.

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At the Peak of Mt Chumstick.
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Section2 Bethel ridge, such an amazing view, ran into a family of MT. Goats too.
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You are having quite the adventure with your build and then some great adventures with it. Thanks for sharing!
 
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New Core 4x4 Rear track bar, Replacing a rough country one, i suspect the soft rubber bushings in the rough country bar were the root cause of the rear steer feeling i was getting shortly after installing it. I'm no longer having that issue with the Core 4x4 bar.

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