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 Post subject: gumbys 91 yj
PostPosted: Fri Jan 02, 2015 6:27 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Figured since I was on this forum now, you fellow jeeples would like to see my rig.

I have had my yj since late 2007 and it has been love ever since.
It started as a wrangler s. With a 2.5 4banger and 5spd.
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this is what she looked like the day I got her

Going to college and working at advance auto parts I started modding. The next February, I bought some presents for my self. At this time it was my daily driver.
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Then I finished college and done more modding. Replaced the 2.5 with another 2.5 that had been bored higher, compression pistons, shaved and ported head and a custom grind cam. Shortly I lost 5th gear, so done a trans swap. Bought me a set of 33x10.5 bfgs for 475 and a rough country 4" lift. It served me 8 years of daily driver service.
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Lucked out and got a lock right locker for the front axle for free, and wheeling has been awesome since. After 10 years of wear and tear, my bfgs dry rotted and one blew out. So I bought a set of bfg km2s.
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I took my extra intake and port matched it to my head, and port matched the 4.0tb and threw it on. The best performance mod i have done was swapping the factory injectors for yellow top ford injectors (sourced from a 98 mustang gt.)

Got a sye, external bell housing swap, and 8.8 with a mini spool to install, just needing the time to get it done. Before the 8.8 goes in, I want to purchase some 4.88 gears.

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Sun Jan 04, 2015 6:15 am 
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Joined: Wed Dec 14, 2011 11:13 pm
Posts: 771
Location: Fort Wayne, IN
Looks good man!

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2004- Jeep Liberty
2016- Jeep Wrangler unlimited
1981- Jeep CJ-5
1977- Jeep CJ-5


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 Post subject: Re: gumbys 91 yj
PostPosted: Tue Jan 06, 2015 2:25 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Enjoy some random wheeling pictures

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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Sun Jan 18, 2015 3:09 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Some photos from my last outting. Almost flipped it in the hole.

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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Fri Jan 30, 2015 2:20 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
So on my home last night, something started roaring. Figured it was a rear wheel bearing by the sound. Got home put it on jack stands and checked it. Rear axle made no noise anywhere. Started it up and ran thru the gears(on jack stands) like normal hiway driving and when it gets around 50mph and faster either the trans or tcase starts screaming. So I guess its time to do all my swap stuff.

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Mon Feb 16, 2015 2:20 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Roaring is fixed. Bad ujoints and some metal wire I didn't catch around the rear pinion.

Need a new steering box. I'm going to run a 98-99 Durango box. Larger, tougher, and better turning ratio.

Since my springs are sagging and beat to hell(installed rough country 4.5 kit in 2007). I'm going to buy better brand springs this time. I have it narrowed down between Rubicon express 4.5 springs or BDS 3.5 springs. BDS does not offer a 4" or 4.5 springs, they do a 5" however. I do not believe I need 5"


So question is any YJ owners on here running the BDS 3.5 springs and running 33's?

I have 33x10.5s on factory rep "ravines".
I WILL NOT run a body lift.
Will the BDS 3.5 be enough to clear?
I do not want to run extended shackles unless I have too.

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Mon Feb 16, 2015 5:37 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Been playing in the snow and also rescuing people.

Symsonia, ky
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Murray,ky
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Cuba,ky
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Wingo,ky
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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Sun Mar 29, 2015 12:22 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
My last wheeling trip before the tear down

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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Sun Mar 29, 2015 12:28 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
The tear down is in progress. Found some frame rot, so no better time than now to fix it.

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Jeep is in the time out corner
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Out with the turdy5, to be replaced with a 8.8
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Old rough country springs out
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And the frame rot
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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Mon Apr 06, 2015 3:33 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Everything has been removed except the engine and front axle. In the process of removing the trans, found that the passenger side engine mount bracket(attaches mount to frame) has broke. I have one on the way from brown dog off road. I will be buying BDS 3.5 springs instead of RE x-duty 4". Have to buy some explorer brake lines for the calipers and axle is set. I'm going ahead and get a rebuild kit for the tcase. I have a new chain and sye, figure I'd replace everything while I'm in there. Taking the trans to a local guy to have it checked out. Have to buy the clutch fork retaining spring and my internal to external swap is complete.

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Tue Apr 07, 2015 2:21 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Eerrrmmaaggaawwdd all the parts. Lol

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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Mon Apr 13, 2015 4:36 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Starting to get parts I have ordered coming in. I have decided to go ahead and re-gear to 4.88 and also change the wheel seals and bearings, now instead of later. Might as well since I will have both axles out at roughly the same time. When I finish bolting the rear together. I will turn the jeep around, pull front axle and re-gear it while I install new springs. While the chunk is out, I will install my new axle seals and swap over to my TJ axles and get rid of my vacuum disconnect and gain the larger u-joints. I'm also going to do the Durango larger steering box. My stock box has a stiff spot in it. This will also be a good time to swap it out too.

Been collecting parts for almost 3years. I'll be glad when its done. Lol

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Wed Apr 15, 2015 12:02 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Rock auto sent the wrong parking brake shoes. My R&P install kits and d30 R&P is here. The 8.8 R&P is going to be late. Still waiting on my springs to get here. I'm getting a 20ton press and have to hunt down a slide hammer to change axle bearings.

This is the mess I'm dealing with at the moment.
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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Tue Apr 21, 2015 1:23 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Good and bad is happening. Summit listed wrong d30 install kit, so having to swap them out. Got the press and slide hammer. New springs came in Friday and jeez, BDS springs are haus cats! Yay! My brake calipers for the 8.8 are rough. The left one pressed back(for new brake pads), the right one however has been soaking in aerokroil and have managed to compress 80% back. Probably going to have to replace it. Axle bearings and seals are yanked out. Frame is fixed and painted. Painted random bits needing paint, and rebuilt and installed the sye.

Calling my transmission guru in the morning to see when we can do a joint teardown and see if my ax5 needs rebuilt.

Still trying to determine if I want to replace the clutch or not(no signs of bad wear). The correct parking brake shoes will be here tomorrow. Still trying to figure out parking brake cable stuff. I'm tired of looking at it on jack stands I'm ready to drive my nanner again. Lol

Here is some pics, because everyone likes pics. :D

Here is my 4.88 motive gear gears. The 8.8 is ginormous compaired to the d30hp.
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My g2 tcase rebuild kit and sye shaft
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This little guy took me 2.5 hours to cut out. He sucks.
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Had to cut down my mode fork since I have a early 231j.
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And the b*stard child is finished. Lol it was actually easy to install the sye. Only hard part was the one bearing.(two photos above)

Still so much to do.

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Wed Apr 22, 2015 1:22 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Coming together slowly. Frame bushings in, gas tank installed with new vent and filler hoses. Hung the front of the springs. Just needing to swap out diff's then set axle in to fab brake lines.


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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Thu Apr 23, 2015 1:02 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
And the 8.8 is naked. Lol

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Hammering out the inner race(the big one) on the pinion, I knicked the diff surface a bit the race sets in. Oops. Some boring filing time now.

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Sat Apr 25, 2015 5:23 pm 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Warrantied out my clutch, bought a bearing splitter and bearing/race/seal driver. Replaced my bearings on the carrier, installed ring gear, installed bearing on pinion.

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Pulled the flywheel off to change the pilot bearing. Got p*missed off trying the grease pack method. Once I pulled it off I was created to this. Yay, freeze plug has been leaking.

Top plug has been leaking. Super suck. More work for me too do.
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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Sun Apr 26, 2015 1:17 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Progress in happening in the forward direction agian. Got the freeze plug changed. It was narshty.

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Here it is fixed. Only clean thing on the engine. Lol

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Got my 4.88 gears installed and set up. Worked perfect with factory shims. Woot woot

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I'm calling it a night. Tomorrow I'll clean out all the grease in the crank snout and bolt the flywheel back on, then new clutch. Progress will be on hold till the trans is gone thru and bolted back in. Can't weld up axle perches till tcase is back in for pinion angle. Getting closer still so much to do.

_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Mon May 04, 2015 1:48 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
So the guy who was supposed to look at my transmission decided at last minute to flake out and not answer his phone. So I said screw it. I put my new front housing on and new bell housing and slapped the trans back in.

Yay new clutch for free. I like when stuff is free
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Internal slave front housing(on floor) and external slave front house. Very nice, yes
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Trans and tcase in, mount bolted up, trans filled full of fluid. Ran out of time today, pick back up this week sometime.
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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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 Post subject: Re: gumbys 91 yj
PostPosted: Tue May 05, 2015 2:43 am 
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Joined: Fri Dec 26, 2014 1:36 am
Posts: 80
Location: west Kentucky
Got a little further tonight. Skid plate/trans mount is on. Tcase filled and rear axle sat on perches. I got jack stands under the ubolt plates so the full weight of the jeep and rest on the springs. I'll let it sit here for a few days to try and settle the springs a bit. Then the tedious time of getting axle centered, and finding pinion angle.

Its starting to look like a jeep again. Getting closer and closer.
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_________________
91 yj- 2.5L bored, cammed, ported intake,4.0tb,ford 19lb injectors,2.5 exhaust, Ax5 4.88 gears 3.5 BDSlift 33x10.5 bfg km2 lock right(front diff) 8.8 rear, sye, external slave, Durango steering box, browndog off-road mounts


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