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2004 Jeep LJ 1 Ton Project - Superduty Swap and Full Traction Long Arm

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  • 2004 Jeep LJ 1 Ton Project - Superduty Swap and Full Traction Long Arm

    Well It was time for me to finally get something with a roof that comes off so I can enjoy the outdoors and air when we go trailriding! So I purchased a highway driven 2004 Jeep LJ (TJ Unlimited) Sport with an automatic. The plan is to use the TJ Rocktrac t-case and Superduty axles off my XJ with wheels and tires and swap them onto the LJ for a clean 1 ton build with good road manners and much better suspension capability for climbing (no binding and wrapping leafsprings).

  • #2
    Short video overview of the stock jeep...I need to come up with a name
     

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    • #3
      First thing we did was the radiator had a leak so to fix it right and prevent any future issues (hopefully) I got an all aluminum radiator replacement.

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      • #4
        Then I started to break everything down after waiting 6 months on Full Traction to get the lift built and sent to me...(I wanted the rear wishbone design and the 4 link front but don't even get me started on how horrible their ownership and operation is....no wonder you cannot buy them anywhere anymore) I tore into the jeep that I had been driving for a while now. Click image for larger version  Name:	IMG_0025.JPG Views:	0 Size:	698.9 KB ID:	11745Click image for larger version  Name:	IMG_0017.JPG Views:	0 Size:	791.3 KB ID:	11746Click image for larger version  Name:	IMG_0022.JPG Views:	0 Size:	523.2 KB ID:	11743Click image for larger version  Name:	IMG_0021.JPG Views:	0 Size:	610.5 KB ID:	11744Click image for larger version  Name:	IMG_0001.JPG Views:	0 Size:	1,002.5 KB ID:	11747
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        • #5
          Then I had the "pleasure" of grinding off and cleaning up the old stock control arm mounts to make room for the new long arm. Click image for larger version

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          Last edited by NavySeal; 10-08-2019, 10:45 AM.

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          • #6
            Boy, you work fast! Saw you were parting out the XJ, and now this. I almost ordered the Full Traction long arm for my XJ, but now that I read their lead time, I'm glad I went with the RE kit. Looks like this will be a slick build!
            - 1988 XJ Base - I don't actually drive it. It just sits in the driveway while I throw parts at it.

            - 1990 XJ Laredo - Old and busted, but it'll get the job done!

            - 1994 XJ Base 2-door - Where'd the other doors go?

            - 1996 XJ Sport - It's red. What else can I say?

            - 1997 XJ Country - My wife wanted something "pretty".

            - 1998 XJ Limited - Cheap and leathery.

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            • NavySeal
              NavySeal commented
              Editing a comment
              Thank you and yes good call on the RE kit...I am getting excited...driveshafts come in Thursday...building some tie rods with 1 ton GM tie rod ends and DOM tube now. I will update with some more pictures soon

          • #7
            Pictures of the XJ getting torn down. It is a little sad but we really had a lot of good memories with him. The LJ will be fun to wheel this fall with the top off

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            • #8
              Loving the progress!
              2004 Grand Cherokee (WJ), Laredo 4.0
              4.5" Frankenstein Short Arm lift, Rusty ADJ CA's, trussed Waggy 44 Front & 44HD Rear; 315/70:17 Patagonia M/T mounted on Micky Thompson Classic Lock II 17x9

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              • #9
                Got the 6 inch Full Traction Long Arm Click image for larger version

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ID:	11792 lift unpackaged and went through the EXTENSIVE parts list...its a lot

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                • #10
                  Also got Rubicrawler in from Advanced Adapters and began the installation before I could finalize the belly pan on the Lift install...had to remove the tail housing off the transmission and install the Rubicrawler in its place...so now I have a true 3 speed case...2.72, 4.0 and 10.88 low range options. So excited Click image for larger version

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                  • NavySeal
                    NavySeal commented
                    Editing a comment
                    Yes!! I just put it in low low the other day and rolled onto the tractor forks to check clearance and wow it is so amazing the control you have! Cant wait to try it on a steep climb. I probably will not use it downhill so I can keep control and be able to throttle out of a tipping situation. Really great options

                  • sjlplat
                    sjlplat commented
                    Editing a comment
                    Do you have a 2-low option with this? I know my twin sticks in the D300 were really handy when I needed to swing things around in tight spaces.

                  • NavySeal
                    NavySeal commented
                    Editing a comment
                    with front manual hubs all three speeds are usable....and then with the transfer case in 2wd I can put the Rubicrawler in its 2.72 low range for a true 2wd low...very neat

                • #11
                  Got the crawler installed finally in a day and the track bar mount

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                  • #12
                    Editors NOTE: We went with the TJ 241OR transfer case after all so we have 3 ratio options and no weak link in the planetary etc. in the 231.
                     

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                    • #13
                      After getting the belly pan installed and getting the front upper control arm mounts welded to the frame I started mocking up the front axle...its so heavy...this was the easy part...the rear is where the "fun" begins getting all the brackets and mounts welded correctly and geometry right Click image for larger version

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                      • sjlplat
                        sjlplat commented
                        Editing a comment
                        I don't know how you get this much done so quick...By the time I've got a bolt-in kit installed, you've already bought, built, wheeled, and sold something twice over.

                      • Gotcha-Again-LOL
                        Gotcha-Again-LOL commented
                        Editing a comment
                        Hahah well thankfully a lot of parts were scavanged from the XJ project...taken a solid 3 months of Dad wrenching hard every weekend and some evenings by himself...I’m amazed how fast he measured and welded everything...I have kids so I couldn’t help him this time around but it’s all good 👍🏻

                    • #14
                      After getting the front really close it was time to tackle the bracketry and fabrication on the rear axle to get the link mounts, coil mounts, shock mounts and center over axle truss for the three link properly centered before welding it all up. Took some time but we got it centered within 1/8 of an inch and after a mock up with everything loose we rotated the truss back quite a bit to get the correct pinion angle. Came out very nice I think.

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                      • #15
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