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Picked up a shitbox!

PRETTY FLIPPING EXCITED RIGHT NOW!! In the box pictured below is a Dana 20 Transfercase that is shipping to Herm the Overdrive Guy to be rebuilt with 3.15 gears. The guy has been communicating really well, doing some googling he has been in the jeep scene for ever, and has been in a few magazines. When I get this back it should get my jeep to an over all crawl ratio of 102.1, which is exactly what I am looking for. My current crawl ratio is 64.8 which is ok, but not great, it's just low enough to almost crawl shit and then spit sputter and die, or ride the clutch!

1st gear- 102.1 : 1
2nd gear- 49.9 : 1

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The jeep is about to go under the knife to get lowered. Last night I removed the coils and lowered it until I liked where it sat. Below is about where it will sit when finished, can't go any lower like this unless I raise the motor up.

Lowered 6".
 

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Opiebennett said:
Looks good at that height.

Mo uptravel = mo problems :laughing:
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When it's done I'm going to leave 4" of up travel on the shocks, but only give it about 1-2" of up at the diff before it hits the bump stop on the front.

I have the DOM and new heims for the rear, going to stretch the rear about 8-10" from where it is now.
 
I got the front spring perches and shock brackets all cut off, cut a small notch in the fender to figure out my angle for the new shock towers. Drew up the new shock towers, about to draw the lower shock tabs. Hoping to maybe mock it up tonight and get the front done this weekend if I have time.


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Got the front coilovers on.... pretty happy. Now I have to re-route the hydraulic lines, install bump stops and limiting straps and the front is 100% done. Going to start on the rear tonight.

Also, I might end up moving the sway bar to the back, I really dont like the sway bar in the front, I like it when the body follows the rear axle better than the front. The sway bar is also limiting my front suspension movement a lot. As of now it only travels about 8" on the front before the sway bar stops it, not a fan at the moment.
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Finally got started on the rear last night. Axle removed, brackets are cut off the axle and ground down the axle. I contacted a mobile hose guy for $150 he will come to me and then build all the lines at $$. He said I'm probably looking at about $350 (that includes his $150 service fee) for all new brake lines and new hydraulic lines. I'm hoping that I get the jeep back together by Sunday and then have this guy come out one day next week.

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Didn't get as far as I wanted over the weekend, ended up having to work Saturday. But did get some work done on the jeep.

Rear axle is now located exactly where it will be, got the new control arms built and installed, got a good plan for the shock placement. Also had a big fajita dinner with a bunch of friends while working on the jeep... good times.

This is the exact location of the rear axle! 114" wheel base, it's about 2-3 inches longer than I wanted, but I felt it was more important to be about 1" past the rear bumper than be 112
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Fajitas and jeep....
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I was going to wait until I had the jeep sitting back on the floor before I posted an update. However, kinda slow this afternoon at work so I figured I would do an update pic. Got the rear coilover brackets all done. Pretty happy with the way it turned out. My phone died last night so I didn't get any pics of it finished. Tonight I am hoping that I get the coilovers on and put all the new bolts in everything. I have to buy a new nitrogen charging station, I had to let the air out of one of the shocks during the mock up. Hoping the new 3:15 transfercase comes in next week.

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Welp, for those that have been following along. Called the mobile hose guy to see if he could come out before the weekend and when it came down to it he didn't want to do it. He wasn't rude, but pretty much let me know that there isn't enough $$ in him coming out at 5:00 PM to do some small hoses. He was like just drop it off at my shop and I'll make them and put them on for you for less $. There is a shop down the road from where I work that I am going to take it to Thursday to have them make all the new lines. Many many years ago I used to make my own lines, but it's always a pain in the dick and I end up not really saving any money.
 
Buy the adapters and fittings now so you can use just straight JIC (preferable) or NPT hoses so that if you blow a line you can keep one long hose on hand that could replace any of your other ones.
If you had time, I would say order them from surplus Center but I doubt you would get them before this weekend.

Aaron Z
 
I removed the rear brake lines from the frame to the axle and taking them to get re-made today. Decided it's kind of dumb to bring the entire jeep in just get get lines remade. I also am going to the local hydraulic shop today to get some hose and fittings (re-usable kind) to make new hydraulic lines for the steering.

I ordered the new muffler and some flexible exhaust pipe from summit this morning. Not sure where or how I am going to mount my exhaust yet, so I am just going to run it with flex to find where I like it then come back and hard pipe it later. The jeep still has the Y pipe right behind the t-case, this is just from that to the muffler and out the back.

I also had to order some bump stops for the front. Last night after looking, I can only have about 1.75" of up travel straight up with the front axle or the upper control arms will get really close to the crank pulley. So, I am going to put a bump stop on the bottom of the frame just above the axle on each side where it sits about 1" off the axle. They are the bullet style, so the tip is kinda soft and they get stiffer as they compress. I figured about 1" off the axle and then about 1/2-3/4" of compression and they will be good. This is only for in a straight up travel scenario where both side depress at the same time, for if I go air born or haul butt down a trail head.
 
aczlan said:
Buy the adapters and fittings now so you can use just straight JIC (preferable) or NPT hoses so that if you blow a line you can keep one long hose on hand that could replace any of your other ones.
If you had time, I would say order them from surplus Center but I doubt you would get them before this weekend.

Aaron Z
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I have a bunch of that stuff in the shop, and probably have enough parts to make what I need, but I'd rather just get them made. I typically have enough parts at camp to rebuild a brake line or 2 when we go offroading.
 
DFW Rusty said:
Got the front coilovers on.... pretty happy. Now I have to re-route the hydraulic lines, install bump stops and limiting straps and the front is 100% done. Going to start on the rear tonight.

Also, I might end up moving the sway bar to the back, I really dont like the sway bar in the front, I like it when the body follows the rear axle better than the front. The sway bar is also limiting my front suspension movement a lot. As of now it only travels about 8" on the front before the sway bar stops it, not a fan at the moment.
Click to expand...

You have some adjustment left on the sway bar. The further away from the pivot point, the less leverage the sway bar has. Some guys make extentions for an even lighter feel.

I'd also think about moving it to the rear.
 
Got the jeep mobile again. It rides frickin nice and I love the stance. Drove it around some embankments that were very off camber and man did it feel stable. Hoping to put the new muffler on tonight, and re-bleed the brakes and then take it on a shake down ride to a small property just a mile away.
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cagcig said:
Was the case you shipped a spare or did you get it back already?
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It was a spare that has been sitting behind the shop for 15 years. I was about to remove and send the one out of this jeep, but after talking to Herm he said they do a complete rebuild with bearings and intermediate shaft I felt it would be silly to do the one in the jeep since I just did new seals on it back in February. I talked to Herm yesterday as a matter of fact and he said it should be ready to ship next week.
 
After almost 52 days I finally got the transfercase back. However, I didn't receive the gear that goes on the back of the transmission. I didn't even realize I was supposed to get one. I fought the transfercase for 30 minutes until, I just knew something wasn't right. Started checking gears and that is when I realized that the gear on the back of the trans is bigger than what will fit the new gears. I did some googling and it looks like I was shorted that gear.

Hopefully that is just an easy fix of send me the gear and move on. The transfercase is really well assembled, they did a great job grinding out the clearance and everything is as smooth as butter! Really excited to get this in. Gears look really good in the case! Tight, but good!
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NEW-
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OLD-
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Crappy pic I know. The long shift rail mount looks like dog shit on there, because I pulled it off the old one and didn't give it a paint job yet.
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Spoke with Herm on the phone. He is getting the gear shipped out today. He even said he might have possibly not put the gear in the package. I absolutely appreciate the honesty and that he is making it right. I get it, everyone is busy right now. As long as he makes it right I am happy as could be.
 
The trans gear just arrived. Herm is a solid guy! I have no doubt that this case will be anything but awesome! I literally cannot wait to get this installed!!!
 

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Fit pretty good! Apparently casting specs were a little sloppy back in the day. The bottom bolt hole was about 3/16" off, had to clearance the t-case hole, but it was only that one hole! Can't wait to get this off the lift this weekend and play with it!
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Took the jeep on a shake down to the local spot and man am I happy! This was the first real test to the suspension work I did as well. The new 3.15 gears are exactly what this jeep needed, I can be sitting almost straight up, dump the clutch with no gas and just let it crawl. 102:1 crawl is perfect. Overall, I am very happy right now, and feel that this jeep is pretty solid and ready for the fall wheeling season to hit!


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