Overbuilding my TJ Rubicon

CV04TJR · Apr 10, 2021

Hi everyone, This is my 2004 TJR that I bought last June. I had been looking for a good low miles relatively stock Jeep to use as my daily driver and starting point for my dream Jeep Build. This is my first time taking on a project like this so I have been reading members build threads and gathering as much information as could from others to put together a solid build plan. When I bought the jeep it came with Warn bumpers front an rear and a Warn 9.5TI winch. The Jeep had also been set up for flat toeing other than that it was all stock. It still had worn out factory shocks and 10 year old tires so the first thing I did was install Rancho RS5000X shocks, Savvy 1.25" body lift, Savvy MML, Savvy TC shifter cable, and new load range C 265/75R16 tires on refurbished Moab wheels.

My jeep before Installed the spring lift.

CV04TJR · Apr 10, 2021

The plan is to keep things mild and use high quality parts. I have put a lot of thought into my build plan and thank everyone for the information that they post and share. I intend to break things into weekend projects since this is my daily.
Phase 1

Savvy 1.25" body lift (done)
Savvy MML (done)
Savvy TC shifter cable (done)
Rancho RS5000X shocks (done)
Goodyear Duratrack 265/75R16 tires (done)

Phase 2

OME spring lift 2934 Front, 2941 Rear (done)
Currie CE-9120 TJJ front track bar (new one with JJ on both ends) (done)
Currie CE9120RS rear track bar (done)
ORO Swaylock (done)
JKS rear sway bar end links (done)
Cycle suspension and adjust bump stops (done)

Jeep after Phase 2 and where I am today.

CV04TJR · Apr 10, 2021

I got 3.5" over sagged factory front springs(coil measures 14.5" installed) and 2" lift from the rear springs(coil measures 10" installed) and a level stance.

I had never heard of cycling suspension until I started researching this build everyone I knew bought a kit and bolted it on. I learned a lot and am glad I spent the time to do it.
Thing I found out.

I needed 2" bumpstop extension on the front for the track bar JJ hosing at the diff hosing, I did grind the gusset to be able to raise the axle that high. I had to add 2 washers to my steering stops to keep tires out of the swaylock endlinks at full stuff.

The track bar just slides past the diff at full stuff.

My shocks are too short. I have 2" of shock shaft left at full bump. 6" off shock shaft at ride height. Rancho RS999128 have 7" of travel so I need longer shocks.

CV04TJR · Apr 10, 2021

That where I am right now. I need to decide on shocks and order parts for Phase 3.
Phase 3

Longer shocks
Savvy control arms
Tom Woods drive shaft
Savvy TC skid

CV04TJR · Apr 23, 2021

I got a few boxes of parts in today. Savvy control arms, steering box skid, Black Magic Brakes Johnny Joint Washers, Barnet diff cover, Currie mini skids, Hubs, front axle u-joints, and ball joints. Looks like I have some work to do.

The Savvy control arms look awesome!

I also order the Savvy TC skid and sliders, I am excited to start getting to put together my dream Jeep after spending the last year planning my build.

CV04TJR · May 2, 2021

I am a little behind on posting but I did take a few steps forward and one step back. Last weekend I replaced my front axle u-joints and hubs because I was hearing a cyclical noise that was getting worse. There was a little play in the DS hub, and the PS u-joint was bad.

The new diff cover is bad A**

New shocks are on too

First time using the hammer method it works really well.

I took the time to disassemble and grease the Johnny Joints on my new control arms. The Currie tools made the job very easy. I do think this was a necessary step as some of the joints were very dry.

The good news is the noise is gone, the bad news is the PS inner axle seal is leaking

. So after doing some research I will be taking everything a part again next weekend to replace the inner axle seals. I left the ball joints alone the first time because they seem to be good but I am thinking that I should just replace them while I have everything apart anyway.

CV04TJR · May 2, 2021

I took some better pictures of my Jeep post lift.

Don A. · May 2, 2021

Nice job, man! Great looking Jeep.

CV04TJR · May 3, 2021

Don Ashcraft said:
Nice job, man! Great looking Jeep.

Thanks, I like how it's turning out.

CV04TJR · Jun 15, 2021

I have a little time so I thought I should update my build. I have not had a lot of time to work on the Jeep lately. I did get my inner axle seals changed out. Thanks to the Forum for giving me the confidence to do this myself, taking the carrier out was the most intimidating mechanical project I have done. It was actually not that bad the worst part was getting it back in the housing.

The leak was my fault. The axle tube was full of sand and dirt, when I put the long side back in after changing my u joint I got sand in the splines which killed my seal.