97 TJ Heep to Zombie Killing Jeep Build by north50

8 minute(s) of a 286 minute read

Removed my CB and over head mount from the now very sad looking, one of these days v8 Jeep. 

As sad as my Jeep looks on the ground begging for attention this poor Jeep is just a waste of one of the best off road vehicles ever made. It shakes the whole building when the stereo is turned up but with 22" wheels and rock rails it just looks ridiculous. 

Was also able to finish cleaning the Dana 30 up and finished painting it. So plan is to get it back together tomorrow.

10-5-2012

Worked on the front axle shaft u-joints today. knocked them out using the THOR method (see video for explanation http://youtu.be/9PpR-DcRV08 ) Worked well and as the pictures show I had some dry caps so was worth the swap especially while they are out of the axle.

Also started to clean up the rear Dana 35 with super 35 kit shafts, ARB and 4.88's to go in the white Jeep.

After first coat of paint, amazing what a little paint can do. Had to paint the yokes for the front axles since the u-joints were out and everything else looks so good.

And this just because it made my laugh.

10-6-2012

Sort of an odd choice but had heard good things and so went with this to paint the axles. Prep work consist of a wire wheel on a drill to get all the big stuff off and smooth out the surface, then paint them up. Also notice the nice new u-joints

Wife is doing ok, she now has lymphedema in her left arm due to the removal of 4 lymph nodes to check if it had spread. Gladly at that time and still today it is believed to have stay contained in her chest tissue. But now has to wear a compression sleeve to help with swelling in her arm. There are so many crazy things that happen to someone with breast cancer that go way beyond the removal of the tumor and chemo treatments as if that isn't bad enough. This being breast cancer awareness month make sure your loved ones do self exams and mammograms.

10-9-2012

Thank You, glad I could be of some inspiration.

So this is working out to be the slowest axle rebuild ever, but it is all the time I have to work on it. 10 minutes here 30 minutes there but like the Jeep progress is being made each step of the way. For instance today I rented a ball joint puller kit from Advanced Auto and after work removed the old ball joints and put in the new ones. I've got to say this has been the biggest PITA of the axle rebuild to this point. But done with them none the less.

Here are the new ones installed.

Also while at Advanced Auto I picked up some diff fluid for both axles. I will be running this in both axles due to the Aussie up front and ARB in the rear.

Tightened the rear diff cover to 30ftlbs in a crossing pattern using a lube locker gasket. So the rear axle is ready to go under the Jeep, just need to finish putting the front together.

http://www.stu-offroad.com/misc/maint.htm

10-19-2012

Progress has been almost non existent but I did manage to get a few things done to the Dana 30. First I had the new bearings pressed on the pinion shaft and carrier.

And finally I have installed the Aussie locker.

10-19-2012

Will be replacing my exhaust manifold this weekend with the following piece I bought on Amazon. It is from APN and has great reviews and only cost $150.

Here are a couple very nice write ups on how to replace your exhaust manifold

http://www.dailydriventj.com/forum/viewtopic.php?t=847

http://www.jeepforum.com/forum/f12/h...ifold-1063245/

10-27-2012

I did get a small amount of time to tinker with the Jeep this evening so started to tear into the engine bay to replace the exhaust manifold. Really wasn't bad at all.

Removed the intake tube.

Then labeled all connections just to be safe

Next I removed the intake and the mount that secures the cables coming to it. Was easier this way, rather than undoing all the cables. just flopped it to the other side of the engine bay.

Then out came the fuel rail with the injectors, Again I left it attached some what and just laid it to the side.

At this point I noticed like others have said some of the O-rings on the injectors stayed in the intake manifold. This is when I started a list of things to buy while I have the jeep tore apart, new O-rings is first on the list.

The one on the right has the O-ring still on it.

The one on the left stayed in the manifold.

The power steering pump was the first thing to slow me down. But after figuring it out it goes pretty smooth. Just loosen the idler below the pulley for the power steering. Then loosen the tensioner bolt that runs behind the idler on an angle. With the belt tension loose you spin the pulley to line up the three bolts holding the pulley and power steering reservoir to the manifold with the holes in the pulley. Again I just left it resting in place once the bolts were out.

With that behind me it was time to crawl under the jeep and remove the bolts holding the manifolds to the block. Then back up top to take the four bolts out and bingo the intake manifold pops out.

I will be giving this manifold a serious cleaning along with the whole engine bay. I plan on doing the MML & BL along with a new valve cover gasket and painting the valve cover itself while I'm at it.

one more bolt and two nuts and the exhaust manifold is off. Was all the time I had tonight, took about 2 hours, not rushing and hunting for a few tools.

Should have this put back together with the new black painted manifold and other things I want done while I'm this deep already.