Hello everyone.
New to this forum, and I posted this question on another Jeep forum, with no replies. Hopeful to gain some insight before I jump in.
The frame on my '98 Sahara has succumbed to O2 poisoning. Time for a swap. Just picked up a reconditioned, rust-proofed, painted 2006 TJ frame. I have several questions, and hopefully the gurus can offer some answers. Thanks in advance for all of your excellent support.
My Sahara is stock as a block, except for the Borla 2 piece header that I installed at 57,xxx miles back in the way early 2000's. I use the Jeep for camping/kayaking/hiking and sometimes as a daily driver for weeks at a time. 5 speed manual, original clutch. Ordered in the late fall of '97, picked up on 10 Jan '98. Some parts are '97 specific, some are '98 and never really know which I will need.
I will do a write up as I am performing the swap, with pics and a view of the actual costs. There is a famous (?) vid on youtube where 3 pros do a complete swap in 5 hours. My timeline is eleven days working 10 hours a day. I will have help here and there but nothing I can count on for long periods of time. Advil and whisky on standby for those intense days.
Now the questions. If there are any suggestions for reasonable upgrades, I would love the advice. Trying to have as much of the replacement/upgrade items on hand so I can roll as fast as possible.
'06 FRAME vs '98 FRAME
Anything that is different between the two other than the steering box and steering box mounting?
STEERING:
I understand the steering box is different from '98 to '06. If I switch to an '06 box, will my hoses and linkage still work? Is it better to modify the mounting and stay with the '98 box? I will be replacing the box either way.
CLUTCH:
Still on the original clutch. Time for a replacement. I have all the bits to do the replacement. Anything else I should be doing while I have the driveline apart? Engine main seal? Should I do the replacement with the engine/trans in the old chassis or in the new chassis? I am thinking in the old.
BUSHINGS:
Should I replace the old suspension and body mount bushings? If so, I will stay with original rubber bushings. Is there a kit? Haven't seen one for the original rubber bushings, seen plenty for poly.
FUEL TANK:
Skid plate is mostly rust and I will install a new skid plate and new straps. Any advice or tips or gotchas? Anything i should do to the tank while I have this level of access?
BRAKE LINES:
I plan to use new stainless lines. Any vendor or brand suggestions? What about mounting clips-is there a kit? Front disc/rear drum, and already have new rotors/discs/shoes all around, plus a new e-brake splitter is already installed.
SHOCKS:
I plan to replace the shocks with stock items. Any suggestions for reasonable upgrade or brands?
CONTROL ARMS:
Can I re-use the originals or should I replace? Upgrade suggestions? I have seen where you can spend *a lot* of money here. Worth it?
EXHAUST/INTAKE MANIFOLD:
I have a leak in the exhaust manifold gasket, and I will replace the gasket. Any tips/gotchas/suggestions here?
ENGINE:
Any other suggestions while I am in there? I have already proactively replaced all of the engine management sensors, and the exhaust is new as well, including the cat, all the way back.
A/C:
The system has a leak. I need to replace the dryer and the o-rings. Not a big fan of the way the hoses connect. Suggestions here on the system?
SUSPENSION:
Stock, and I will keep it stock. Any suggestions or tips for minor upgrades here or maintenance items I can do while it's all accessible?
RADIATOR:
Not overly fond of the plastic in the OEM item, and this is the second radiator. Suggestions for an upgrade here? I will likely not stay with stock.
INDISPENSABLE TOOLS:
Suggestions here? I don't have an impact wrench, do have a pancake compressor. Still need to get a cherry picker and some spring compressors. Have torque wrenches and pulley/pitman/ball joint pullers, and a good collection of tools, both metric and SAE. Have oxy/acetylene and propane torches, vacuum pump and refrigerant gauges and refrigerant.
TORQUE SPECIFICATIONS:
Where do I find the detailed torque specs for each of the systems? What is the best system to visually ensure I have torqued everything to spec-a dab of white paint on the bolt upon successful torque application?
ADDITIONAL INFO:
Any other suggestions or advice will be most welcome. I am just a home mechanic. I will treat this like any other large project-as a series of smaller projects, logically completed in series until overall project finalization.
Here is my plan:
Run the fuel down as low as possible. Liquid Wrench the hell out of the entire underbody for about a week. Drain engine oil, coolant, refrigerant, brake and ps fluids. Lift the Jeep and lower onto the wheel dollies, using chocks for brakes and leaving the trans in neutral. Remove the battery. Remove the soft top, rear seat, doors, spare, and any other extraneous weight. Unbolt and disconnect all systems and bolts between the chassis and the body (it's a bit of a list). Raise the body off the chassis with the lift and leave body lifted for the duration. Roll the chassis to the open garage bay and next to the replacement chassis. Disconnect the exhaust at the downpipe. Replace the exhaust/intake gasket. Replace clutch. Pull engine/trans/transfer case and move aside. Begin moving systems from the old chassis to the new (not sure of the order I should do this and would appreciate advice). Should I do brake lines first or last or somewhere in the middle? Should I do fuel system first or last or in the middle? Suspension and axles first, last, middle? Which way makes most sense? Once all systems are replaced and all bolts are torqued and double checked, will install the engine/trans/transfer case and axles into the replacement chassis. Will roll the completed chassis under the lifted body and reinstall the body to the chassis and reconnect all systems. Bleed and fill brakes. Bleed and fill clutch. Bleed and fill ps. Bleed and fill coolant. Vacuum and recharge A/C. Replace battery.
Sorry for the long post, and again I thank you all in advance for any and all suggestions, support, tips, and advice.
Garrett
New to this forum, and I posted this question on another Jeep forum, with no replies. Hopeful to gain some insight before I jump in.
The frame on my '98 Sahara has succumbed to O2 poisoning. Time for a swap. Just picked up a reconditioned, rust-proofed, painted 2006 TJ frame. I have several questions, and hopefully the gurus can offer some answers. Thanks in advance for all of your excellent support.
My Sahara is stock as a block, except for the Borla 2 piece header that I installed at 57,xxx miles back in the way early 2000's. I use the Jeep for camping/kayaking/hiking and sometimes as a daily driver for weeks at a time. 5 speed manual, original clutch. Ordered in the late fall of '97, picked up on 10 Jan '98. Some parts are '97 specific, some are '98 and never really know which I will need.
I will do a write up as I am performing the swap, with pics and a view of the actual costs. There is a famous (?) vid on youtube where 3 pros do a complete swap in 5 hours. My timeline is eleven days working 10 hours a day. I will have help here and there but nothing I can count on for long periods of time. Advil and whisky on standby for those intense days.
Now the questions. If there are any suggestions for reasonable upgrades, I would love the advice. Trying to have as much of the replacement/upgrade items on hand so I can roll as fast as possible.
'06 FRAME vs '98 FRAME
Anything that is different between the two other than the steering box and steering box mounting?
STEERING:
I understand the steering box is different from '98 to '06. If I switch to an '06 box, will my hoses and linkage still work? Is it better to modify the mounting and stay with the '98 box? I will be replacing the box either way.
CLUTCH:
Still on the original clutch. Time for a replacement. I have all the bits to do the replacement. Anything else I should be doing while I have the driveline apart? Engine main seal? Should I do the replacement with the engine/trans in the old chassis or in the new chassis? I am thinking in the old.
BUSHINGS:
Should I replace the old suspension and body mount bushings? If so, I will stay with original rubber bushings. Is there a kit? Haven't seen one for the original rubber bushings, seen plenty for poly.
FUEL TANK:
Skid plate is mostly rust and I will install a new skid plate and new straps. Any advice or tips or gotchas? Anything i should do to the tank while I have this level of access?
BRAKE LINES:
I plan to use new stainless lines. Any vendor or brand suggestions? What about mounting clips-is there a kit? Front disc/rear drum, and already have new rotors/discs/shoes all around, plus a new e-brake splitter is already installed.
SHOCKS:
I plan to replace the shocks with stock items. Any suggestions for reasonable upgrade or brands?
CONTROL ARMS:
Can I re-use the originals or should I replace? Upgrade suggestions? I have seen where you can spend *a lot* of money here. Worth it?
EXHAUST/INTAKE MANIFOLD:
I have a leak in the exhaust manifold gasket, and I will replace the gasket. Any tips/gotchas/suggestions here?
ENGINE:
Any other suggestions while I am in there? I have already proactively replaced all of the engine management sensors, and the exhaust is new as well, including the cat, all the way back.
A/C:
The system has a leak. I need to replace the dryer and the o-rings. Not a big fan of the way the hoses connect. Suggestions here on the system?
SUSPENSION:
Stock, and I will keep it stock. Any suggestions or tips for minor upgrades here or maintenance items I can do while it's all accessible?
RADIATOR:
Not overly fond of the plastic in the OEM item, and this is the second radiator. Suggestions for an upgrade here? I will likely not stay with stock.
INDISPENSABLE TOOLS:
Suggestions here? I don't have an impact wrench, do have a pancake compressor. Still need to get a cherry picker and some spring compressors. Have torque wrenches and pulley/pitman/ball joint pullers, and a good collection of tools, both metric and SAE. Have oxy/acetylene and propane torches, vacuum pump and refrigerant gauges and refrigerant.
TORQUE SPECIFICATIONS:
Where do I find the detailed torque specs for each of the systems? What is the best system to visually ensure I have torqued everything to spec-a dab of white paint on the bolt upon successful torque application?
ADDITIONAL INFO:
Any other suggestions or advice will be most welcome. I am just a home mechanic. I will treat this like any other large project-as a series of smaller projects, logically completed in series until overall project finalization.
Here is my plan:
Run the fuel down as low as possible. Liquid Wrench the hell out of the entire underbody for about a week. Drain engine oil, coolant, refrigerant, brake and ps fluids. Lift the Jeep and lower onto the wheel dollies, using chocks for brakes and leaving the trans in neutral. Remove the battery. Remove the soft top, rear seat, doors, spare, and any other extraneous weight. Unbolt and disconnect all systems and bolts between the chassis and the body (it's a bit of a list). Raise the body off the chassis with the lift and leave body lifted for the duration. Roll the chassis to the open garage bay and next to the replacement chassis. Disconnect the exhaust at the downpipe. Replace the exhaust/intake gasket. Replace clutch. Pull engine/trans/transfer case and move aside. Begin moving systems from the old chassis to the new (not sure of the order I should do this and would appreciate advice). Should I do brake lines first or last or somewhere in the middle? Should I do fuel system first or last or in the middle? Suspension and axles first, last, middle? Which way makes most sense? Once all systems are replaced and all bolts are torqued and double checked, will install the engine/trans/transfer case and axles into the replacement chassis. Will roll the completed chassis under the lifted body and reinstall the body to the chassis and reconnect all systems. Bleed and fill brakes. Bleed and fill clutch. Bleed and fill ps. Bleed and fill coolant. Vacuum and recharge A/C. Replace battery.
Sorry for the long post, and again I thank you all in advance for any and all suggestions, support, tips, and advice.
Garrett