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Author Topic: 04 TJ Unlimited build  (Read 7808 times)

hes4all

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04 TJ Unlimited build
« on: July 03, 2012, 09:16:49 PM »
Here are some more pictures of my 04 TJ Unlimited build. I hope to be done in about 6-8 weeks. I can give you more specifics if you want them. I will tell you that with 42" tall tires, this is going to be one low Jeep.
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

Water Dog

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Re: 04 TJ Unlimited build
« Reply #1 on: July 31, 2012, 09:25:02 PM »
Looking foreward to seeing the finished product Terry. Be sure and post pics. BTW, have you ever done an 8.8 differential swap?
Dennis

"Heart is where the home is"
---------------------------------
Dennis & Vici Bernhard
2000 Bounder
1999 Jeep Wrangler
Home: Sumner, TX

John Canfield

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Re: 04 TJ Unlimited build
« Reply #2 on: August 03, 2012, 09:39:58 AM »
Love to see build pictures!
--John
2005 Horizon 40AD, 2006 Jeep Rubicon Unlimited
Our Horizon projects
Our weather

hes4all

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Re: 04 TJ Unlimited build
« Reply #3 on: November 02, 2012, 10:49:10 PM »
Finally got a little more done on my Unlimited. Here are a few picks for you.
What do you think of sloping the grill?
« Last Edit: November 02, 2012, 11:14:11 PM by hes4all »
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

John Canfield

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Re: 04 TJ Unlimited build
« Reply #4 on: November 03, 2012, 09:17:02 AM »
What do you think of sloping the grill?

Don't know.  I'd need to see a few more pix to get a better feel assuming you're doing that for cosmetic reasons.

Who made the front axle?  The build looks really good. 

I would love to reposition my shocks to the top of the axle - I'm always beating up the hangars.

--John
2005 Horizon 40AD, 2006 Jeep Rubicon Unlimited
Our Horizon projects
Our weather

hes4all

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Re: 04 TJ Unlimited build
« Reply #5 on: November 03, 2012, 10:26:06 AM »
Good morning John, well I am going to slope the grill a little to make more room for me to access my winch. This build has gotten to the point of almost too much. If you look at the picture below, you will see a line on the frame rail where I cut it off. I added on channel to make the frame go straight instead of turning out like the stock frame does. So to have a little more room to tuck the  winch in between the frame rails and the biggest reason for me doing this is to keep a better turning radius and because i can (lol). I will put up a few pictures of the front when I get more done. The axles or Dana 60 Roc Jocks. Just plugging along, thanks!
« Last Edit: November 03, 2012, 11:27:57 AM by hes4all »
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

SVTotem

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Re: 04 TJ Unlimited build
« Reply #6 on: March 04, 2013, 09:01:49 AM »
Terry, Here is a simple mod you might want to do the next time you have time on your hands if you have an automatic. The transmission linkage separated leaving me in reverse half in the garage. It seems this plastic part will fail, just a matter of time. Mine failed at 73K miles. Luckily I found this thread on jeepforum before I called for a tow. I will always carry zip ties on board now, too.

http://www.jeepforum.com/forum/f9/05-4spd-auto-linkage-failure-600665/

Bill
Bill Burgner
'13 Tiffin 36GH, 05 Wrangler LJ Rubicon, Aventa II & Air Force One
www.retirement-ramblings.blogspot.com

John Canfield

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Re: 04 TJ Unlimited build
« Reply #7 on: March 04, 2013, 04:38:43 PM »
That's a new one on me!  I'll have to look into that mod.
--John
2005 Horizon 40AD, 2006 Jeep Rubicon Unlimited
Our Horizon projects
Our weather

SVTotem

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Re: 04 TJ Unlimited build
« Reply #8 on: March 05, 2013, 10:33:44 PM »
Just finished it today. I ground the round rivet head like back side of the nipple to get a good drilling surface. Once drilled out and reassembled with the clevis pin and nylon washers it works like a charm. I went with a cotter pin rather than a spring clip. It just seemed more secure.
Bill Burgner
'13 Tiffin 36GH, 05 Wrangler LJ Rubicon, Aventa II & Air Force One
www.retirement-ramblings.blogspot.com

hes4all

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Re: 04 TJ Unlimited build
« Reply #9 on: March 05, 2013, 10:51:08 PM »
Thank you Bill. I will check it out for sure. Hope to post a few more pictures soon. Thanks again.
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

hes4all

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Re: 04 TJ Unlimited build
« Reply #10 on: April 23, 2013, 08:43:49 AM »
And the build continues. Just got the control arms back from the powder-coater. They look nice for now if you know what I mean?

Just one more weld on the front axle and some paint and then install it for the last time I hope. I have had it in and out six times so far. Starting to paint front shock towers too.

I think I will be done by July 1st.
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

John Canfield

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Re: 04 TJ Unlimited build
« Reply #11 on: April 23, 2013, 06:12:41 PM »
Looking good Terry!  Whose shock towers are those?

I just finished up on my front axle, just minor mods.  I now have Clayton lower control arm brackets instead of OEM and I converted the axle end of the upper control arms from bushings to the Currie kit with the Johnny Joints.  Rubi is loaded on the trailer and we are working our way to Moab starting Thursday for the FMCA 4-Wheelers rally.  Whoo-hoo.
--John
2005 Horizon 40AD, 2006 Jeep Rubicon Unlimited
Our Horizon projects
Our weather

hes4all

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Re: 04 TJ Unlimited build
« Reply #12 on: April 25, 2013, 08:50:11 AM »
Hi John, A friend of mine cut those out for me. I just gave him a template and 15 minute later I had them. He has a nice CNC Plasma table.

The Johnny Joints are nice. Have them on the bosses Jeep and the one I am building. I really hope to get this done in a few months?

Clayton does make some nice stuff too! So you didn't three link the front?
Maybe down the road?

Have fun and safe travels to you guys!
And yes, WHOO-HOO
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

John Canfield

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Re: 04 TJ Unlimited build
« Reply #13 on: April 26, 2013, 08:04:58 AM »
CNC Plasma table - DROOL... (I have the plasma torch, just need the expensive part  :D )

Yeah, the guys on Rubicon Owner's Forum have also been asking why I didn't three-link the front  :o.  Not enough time, for one.  I might see about having the 4x4 shop in Montrose, CO give me a quote on a three-link - we'll be there for about a month this summer.
--John
2005 Horizon 40AD, 2006 Jeep Rubicon Unlimited
Our Horizon projects
Our weather

hes4all

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Re: 04 TJ Unlimited build
« Reply #14 on: April 27, 2013, 02:52:10 PM »
I am in the same boat John. Have the Plasma but need the table. I have been looking at them for about a month now. I have to say that it is kind of funny where they (Plasma table companies) start off with the price. Every week they quote me a new lower price.

And yes, three link is the way to go! It really frees up the front articulation. The biggest thing IMHO is to keep the drag link and track bar in the same angle. This will keep steering nice. I drive my Jeep everywhere and have know problems at all.

Have fun :)
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

dhfinc

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Re: 04 TJ Unlimited build
« Reply #15 on: April 30, 2013, 06:42:13 AM »
My boys just got a Torchmate plasma table. Some learning curve involved, with the software/computer/table interface. It looks to be a fun very creative metal fab tool.
08 Wrangler Rubicon
06 DSDP Newmar

zmotorsports

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Re: 04 TJ Unlimited build
« Reply #16 on: April 30, 2013, 08:16:56 AM »
Very nice looking.  Can't wait to see the finished product.  Oh wait, stupid me, it's a Jeep.  They are never "done".

Mike.
2003 Monaco Dynasty Baroness
2011 Jeep Wrangler Unlimited
FMCA# F315002

hes4all

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Re: 04 TJ Unlimited build
« Reply #17 on: May 01, 2013, 11:19:00 AM »
My boys just got a Torchmate plasma table. Some learning curve involved, with the software/computer/table interface. It looks to be a fun very creative metal fab tool.

I have spent a lot of time looking at the Torchmate. But I would have to say that I am leaning towards the Plascam unit mainly because of the software.

Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

hes4all

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Re: 04 TJ Unlimited build
« Reply #18 on: May 01, 2013, 11:23:14 AM »
Can't wait to see the finished product.  Oh wait, stupid me, it's a Jeep.  They are never "done".

Mike.

I think this is on a shirt! :)

Thanks Mike, been a long time coming but it will be worth it? I think!
Just got my seats so that should be the last of ordering stuff.

And I had some computer changes done and should have it back today!
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

SVTotem

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Re: 04 TJ Unlimited build
« Reply #19 on: May 02, 2013, 12:19:51 PM »
Computer changes? Tell us more!
Bill Burgner
'13 Tiffin 36GH, 05 Wrangler LJ Rubicon, Aventa II & Air Force One
www.retirement-ramblings.blogspot.com

hes4all

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Re: 04 TJ Unlimited build
« Reply #20 on: May 03, 2013, 08:20:02 AM »
OK, with the size tire that I am running I had to do a large cut out of the rear fenders. I don't know about other LJ’s, but the 2004 model has two canisters in the left rear that I now have very little room for. With the changes on the computer I can now run one of the canisters instead of the two. This will say me a ton of time having to fab a place to move them too.
And because I am so anal about ride height, I can now relocate the oxygen sensors too. This will help me with the front drive shaft.
I wish I could add 100 hp but that will not happen. The computer will come back with no memory so I can affect how it will “learn”. Kind of like the Allison trans in coaches.
On my DW Jeep (2001 TJ) I have gone through the sequence on clearing the computer and have had a noticeable jump in power. I know that each year has a different sequence but with her Jeep this is the sequence.
1.   Disconnect the battery cables and hold them together for 30 second.
2.   Reconnect them back to the battery.
3.   Turn the key on (don’t start).
4.   Turn on headlights.
5.   You will wait for two to three minutes
6.   Then the check engine light will blink either 11 or 13 times, depends on standard or automatic trans.
7.   Start engine….it will run rough for a minute or two but will smooth out.
8.   Now drive the crap out of it demanding performance. Drive it hard. Now your  computer has learned new parameters.
Good luck
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

SVTotem

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Re: 04 TJ Unlimited build
« Reply #21 on: May 03, 2013, 09:14:13 AM »
I think I will give that reset a try. I am experiencing driveabilty issues usually mentioned in threads about gearing when going to larger tires, but I am still at stock 245/75R16. Hopefully, that sequence will work on the 05. Do you know where that is documented for the various years?
Bill Burgner
'13 Tiffin 36GH, 05 Wrangler LJ Rubicon, Aventa II & Air Force One
www.retirement-ramblings.blogspot.com

hes4all

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Re: 04 TJ Unlimited build
« Reply #22 on: May 03, 2013, 10:04:08 PM »
Hi Bill, I didn't get this off the web. Was on a wheeling trip and meet a guy that was a engineeer for Chyrsler. He shared this info with me and a few buddies. He said that during the build process the computer never gets a real picture of driving. The engine is never worked so that is a base starting point for the vehicle. Over time, the program will change some but this will do it faster. He said that you need to drive the #$%@ out of it when you do it. Don't just go for a cruise or you will be right where you started.

I hope it does work for your year Jeep. Let me know!
Terry and Janelle
Jeep Wrangler TJ
2 grand babies who will be Jeepers?
There's Life in the Red (read) Letters, Idaho

SVTotem

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Re: 04 TJ Unlimited build
« Reply #23 on: May 04, 2013, 12:55:18 PM »
I will give this a try soon, but we are out camping with the grandniece this weekend. Then my next project is installing the new Trektop NX.

I will post back my results. How long does it take to learn the pattern? Does one outing do it, or do I just change my driving habits for a while until I notice a change? It is hard to get too crazy around town.
Bill Burgner
'13 Tiffin 36GH, 05 Wrangler LJ Rubicon, Aventa II & Air Force One
www.retirement-ramblings.blogspot.com