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Thread: 97 ZJ Garage to Trail Project

  1. #1
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    Default 97 ZJ Garage to Trail Project



    I bought a ZJ that had been sort-of built as a crawler, but had some problems. It had the one major upgrade that I wanted, and that was a long arm suspension kit with sway bar disconnects. It had an OX locker in the front (just found out it is bad) and needed a rear diff (kinda think these issues might be related.) It was not driving when I bought it, but it started right up and runs fantastic. The rest of the jeep is in perfect condition, so I figure that it will make a good project to get the family into the outdoors and off road.

    My goal is to have a safe reliable Jeep that I can drive from my house at hwy speeds and get into some fun trails with friends. Not planning on running crazy crawling adventures, but I want it to be rugged and reliable enough to get out of a sticky situation if needed. I think that the ZJ with the 5.2 is a good platform for both on and off road stability, and it has the power to get through some tough stuff if needed.

    Last fall: Replaced the shot Dana 44A with a Ford 8.8. The bearing blew up and the carrier shifted over ahd ground away the side of the aluminum journal, so probably not a great idea to rebuild it. I had the axle built by SFF customs, but I am probably going to open it up after reading some reviews and noticing that it is already noisy. Here are some install pics.
             

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    Default Re: 97 ZJ Garage to Trail Project



    Tore the NP249 out, and took the new NP231 apart. Everything was in really good shape, but the plastic cage on the main input bearing had shattered. I am not sure why anyone would put a plastic cage on a bearing... taking it out was really smooth. I had the 249 out in about 30 minutes and it took me about 4 hours today to completely strip and clean the 231. I put in all new seals. Now I just have to wait for the input bearing to put everything back together.
         

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    Default Re: 97 ZJ Garage to Trail Project



    Any thoughts on going SYE on the 231 since you got it out anyway? I have a NP241 and did the conversion and it was pretty easy.

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    Default Re: 97 ZJ Garage to Trail Project



    A note on the SYE, Bill's Englewood Drive Shaft is a member on here and offers a good deal on SYE and drive shaft. Quick turnaround and excellent service with incredible quality. I will leave a link to him at the end for when you are ready. I ran 6" lift on my XJ and was replacing ujoints on a regular basis until installing the kit. I have considered this swap for my 98 ZJ but have grown used to the AWD and it really launched nice at the track with it.
    http://www.billsenglewooddriveshaft.com/
    ___________
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    Default Re: 97 ZJ Garage to Trail Project



    Doink previously posted:
    "Any thoughts on going SYE on the 231 since you got it out anyway? I have a NP241 and did the conversion and it was pretty easy."

    I want to, and might have the cash to do it now. I found the front axle that I needed for cheaper than I thought and I am picking it up today. I wanted to do the swap from the beginning, but the boss limited the funds.

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    Default Re: 97 ZJ Garage to Trail Project



    xaza previously posted:
    "A note on the SYE, Bill's Englewood Drive Shaft is a member on here and offers a good deal on SYE and drive shaft. Quick turnaround and excellent service with incredible quality. I will leave a link to him at the end for when you are ready. I ran 6" lift on my XJ and was replacing ujoints on a regular basis until installing the kit. I have considered this swap for my 98 ZJ but have grown used to the AWD and it really launched nice at the track with it.
    http://www.billsenglewooddriveshaft.com/"

    I am going to send him a message now. Thanks for the info.

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    Default Re: 97 ZJ Garage to Trail Project



    Got a new front axle today. It is a dana 30 HP with Aussie Locker. I would like a selectable locker in the front, but I will make due. It is not a daily driver. I pulled it apart and everything looked really good. I started to transfer over parts to the new axle. Jeep looks pretty naked without any front suspension.
           

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    Default Re: 97 ZJ Garage to Trail Project



    Got a question: The long arm lift kit has some eccentric bolts and slotted mounts that were welded to the old axle. It that a critical adjustment for the lift? I would rather just hard mount it and make very accurate measurements to align the axle. I still have overall length and angle adjust-ability, though it will be more tedious.

    Basically it is this part welded on in place of the lower control arm mount. You can adjust it back and forth without threading in the rear insert. Not sure I want or need that adjustment. I am going to read up on it, but any advice would be appreciated.

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    Default Re: 97 ZJ Garage to Trail Project



    nice axle upgrades! I recently resealed my NP231 and switched it to Mobil1 10w30. I got the idea here: http://www.novak-adapt.com/knowledge...er-cases/np231

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    Default Re: 97 ZJ Garage to Trail Project



    That is a cam bolt setup. I chased issues with the cam bolts coming loose on my truck for a long time. Eventually we got them tight enough to stay in place. It will have a bolt with a flat side and an offset washer of sorts. Here is a picture of the hardware in case you are missing them.
    http://www.spohn.net/shop/2003-2011-...o7kaAvkz8P8HAQ
    ___________
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    Default Re: 97 ZJ Garage to Trail Project



    Danimal previously posted:
    "Got a question: The long arm lift kit has some eccentric bolts and slotted mounts that were welded to the old axle. It that a critical adjustment for the lift? I would rather just hard mount it and make very accurate measurements to align the axle. I still have overall length and angle adjust-ability, though it will be more tedious."

    You have it right, you can adjust caster with your aftermarket arms.

    It is hard to tell in the picture, but you want to reinforce your passenger side upper control arm mounting bracket on the replacement axle. I fixed a stock bracket that had ripped off using a similar control arm set-up.

    ___________
    The Lost Boys motto: We don't know where we're going, but we'll be there for awhile. :)

  12. #12
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    Default Re: 97 ZJ Garage to Trail Project



    xaza previously posted:
    "That is a cam bolt setup. I chased issues with the cam bolts coming loose on my truck for a long time. Eventually we got them tight enough to stay in place. It will have a bolt with a flat side and an offset washer of sorts. Here is a picture of the hardware in case you are missing them.
    http://www.spohn.net/shop/2003-2011-...o7kaAvkz8P8HAQ"

    Thanks, That is something that I was worried about. I think that I am just going to get rid of them and make adjustments on my control arms. Mostly if I am torquing and flexing I don't want to worry about them rotating and causing problems. Those are exactly the bolts that were on there.

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    Default Re: 97 ZJ Garage to Trail Project



    Do the she now, and you might want to do the 2wd-lo shift conversion.
    Its a few hundred bucks but we'll worth it.
    Bills does a nice drive shaft for sure.
    ___________
    Crazy- You call me crazy, but you wouldn't know crazy if Charles Manson was eating Fruit Loops on your front porch. Suiciadl tendancies- intatutionalized

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    Default Re: 97 ZJ Garage to Trail Project



    dieseldoc previously posted:
    "Do the she now, and you might want to do the 2wd-lo shift conversion.
    Its a few hundred bucks but we'll worth it.
    Bills does a nice drive shaft for sure."

    Wow, I did not even know that the 2Low kit existed.

    I got my new axle all checked out and most of the way installed over the weekend. I might have the money leftover for the doing this. But now I am getting a little antsy to get the jeep done and get out and drive it.

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    Default Re: 97 ZJ Garage to Trail Project



    I feel ya.
    My 3 day weekend is and axle rebuild/regear wrench test.....got to get this stuff done so we can wheel the anniversary run!
    ___________
    Crazy- You call me crazy, but you wouldn't know crazy if Charles Manson was eating Fruit Loops on your front porch. Suiciadl tendancies- intatutionalized

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    Default Re: 97 ZJ Garage to Trail Project



    dieseldoc previously posted:
    "I feel ya.
    My 3 day weekend is and axle rebuild/regear wrench test.....got to get this stuff done so we can wheel the anniversary run!"

    I got the axle under the jeep and roughly aligned on Monday night. I think that the parts for the NP231 should be here this week, if they are I should be able to button everything up and get an alignment.

    What / when / where is the anniversary run? I want to get a couple hundred miles on everything and change the fluids before I start really wheeling it, hopefully I can get that done and start hitting the trails with some of you guys.

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    Default Re: 97 ZJ Garage to Trail Project



    Looks good man, you're making some great upgrades. In addition to the brace Hypoid mentioned, you might consider some Lower control arm mount Skids. The LCA mounts are easier to bend than you'd think and adding skids does wonders for keeping your mounts straight and suspension geometry in line.

  18. #18
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    Default Re: 97 ZJ Garage to Trail Project



    Well today was a productive damn day. I got the main input bearing for the NP231 so I assembled it and got it ready to install. While it was drying I finished up the front end and got brakes and steering installed. I still need some lock nuts for the steering, but I will get them tomorrow if ACE is open.
          

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    Default Re: 97 ZJ Garage to Trail Project



    I then got the NP 231 installed and replaced the rear main seal on the transmission. That was a little more fun for one person than I was planning on having, but it is in there working perfectly. One thing to note about changing the wiring for the transfer case swap. I have a 1997 ZJ limited. Not sure where things changed, but the center console was screwed to the dash board inside behind the glovebox. I had to pull the whole thing to get the cover off. It was not too bad all things considered, but don't try to pry the black bezel off to get to the main display behind. After that it was just a mater of finding the plugs to swap.
          

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    Default Re: 97 ZJ Garage to Trail Project



    I got the jeep out of the garage today and drove it around the block to let the suspension settle. Not going to lie, 2WD is awesome and I do not even hear the Aussie Locker at all. Everything feels awesome!

    Next things that I need to do are:
    1) Upgraded Sway Bars
    2) Armor under the transmission and transfer case
    3) armor for lower control arm mounts
    4) rebuild rear differential
    5) SYE and drive shaft

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