Jeep Front End

Like any Jeep project, the scope has a tendency to severely creep. I determined that this would be an excellent time to replace my spring packs since everything was going to be torn apart. The bonehead that I purchased the Jeep from had installed an add-a-leaf (or two!) on each leaf spring and added enormous shackles measuring over 7". It's difficult to say exactly what had been done but, each front spring had 8 leaves and each rear had 9! Yeouch!! Talk about a harsh ride! To make matters worse, he also welded on a few "extra" shock mounts totalling three (3) shocks per front wheel and two (2) shocks per rear. In addition, there were also three (3) steering stabilizers.

Just as with the Chevy 350 conversion, the first step was to remove EVERYTHING. I started with the shocks and then removed the steering stabilizers and tie rods. The next step is where I goofed; I removed the U-bolts holding the axle to the springs. I should have left the axle housing attached to the springs until I had removed the steering knuckles. It would have made it much easier to have removed the axle components if everything was firmly attached to the springs. Oh well, chalk one up to experience. After removing everything, I found that the shocks were still in decent condition. However, the stabilizers were completely blown. In fact, they were so dry that the pistons slid in and out effortlessly. Needless to say, everything needed to be replaced. Since the Jeep appeared to have approximately 4" of lift, I ordered new 4" Skyjacker springs, double-tube steering stabilizer, and stock length shackles. Since I had everything torn apart, I decided that I should replace the shocks. I purchased new Rancho RS9000 adjustable shocks with the in-cab controller. I have provided a convenient Rancho shock chart if you wish to find the appropriate shock part numbers for your particular vehicle.

Anyway, I pulled out my angle grinder and went to town on the "extra" shock mounts. A Jeep is such a light vehicle that there's no way they should require multiple shocks unless you had a LOT of extra weight on the front like a heavy plow. In my case, they were making the ride way too harsh and I decided that they must go. There are still extra mounts on the rear; however, I won't have access to grind them off until I remove the tub again. So, in the mean time, I will just remove the second shock from each side in the rear and leave the mounts in place.

After I removed the front axle and pulled all of the parts off of it, I took it outside and let it drain into a bucket. To my dismay, I notifed a couple of chipped teeth in the differential's ring gear. This was a serious bummer since I dont't want to dump money into the actual differentials since I eventually want to swap in Dana 60's. Since the axles had a 3.73 ratio, I decided that the best, most cost-effective solution would be to swap in a set of used gears as I figured they would be a dime a dozen; most people swap them out in favor of lower gears. I immediately posted a message to rec.autos.makers.jeep+willys and found someone willing to sell a set on low-mileage, Dana gears for $50. Whew! Even so, swapping ring and pinion gears requires a skill that I personally don't have. I plan on looking for a shop that will swap it in for me.

Once everything was finally removed from the front half of the frame, I slapped on a couple coats of POR-15 rest preventative paint on everything to kill to rust monster. If you haven't used POR-15, then get on the bandwagon and check out their web site. I bolted on my new 4" Skyjacker springs and new shackles, spring hangers, and urethane bushings and bolted the axle housing to the springs. I also bought new seals and bearings for the front axle since it was apart. Since I wanted to tighten up the steering, I wanted to put new ball studs in the steering arms. I was able to remove the old studs with a small sledge hammer and a drift; however, I wasn't able to easily insert the new ones. I broke down and took the steering arms and new studs for a shop to have them installed for $85 ... YEOUCH! I think they charged me way too much but, I was in a bind.

After I got the ball studs installed, I was able to put the axle back together and install the steering linkages. I used urethane tie rod boots to help protect them but, I'm not sure that they will actually do much. I bolted on a new, rebuilt steering gear ($160) with a dropped pitman arm ($40) to help alleviate some of the stresses encountered with running large tires. When I tried to put the brake calipers back on, they appeared to be seized in the "clamped" position. Not matter what I did, no matter how large the C-clamp, it was impossible to close the piston. Fearing the worst, I went up to the local AutoZone and bought a rebuilt pair of front disc calipers for $40! I couldn't believe how cheap they were since 4WDH listed them at $30 a piece and Quadratec listed them at $70 a piece!

Once I had the new brakes assembled with new pads, I threw the tires back on to get it ready to accept the freshly rebuilt Chevy 350.





To be continued ...



<RANT mode ON>
DO NOT PURCHASE FROM FOUR WHEEL PARTS WHOLESALERS!!
They have the absolute worst customer service and shipping departments. I ordered my shocks on a Tuesday and told them that I HAD to have them by Friday. I was willing paid for 2nd Day UPS service so that I could have them in time. When I called them for a tracking number the next day, they said that everything went out and gave me the number. I contacted UPS and found out the package went normal Ground and was scheduled to be delivered on the following Monday! Argh! I immediately called 4WPW (Wednesday) and complained about the problem. They said that they could take care of the problem by shipping an identical package for me and send it Next Day Red Label (they would cover shipping). I agreed and waited for the package. When Friday rolled around, there was no sign of my package so I called 4WPW back to get the tracking number. I called UPS and again they said, "That package was sent Ground and is scheduled to be delivered next Wednesday." Needless to say, I was EXTREMELY irate and I immediately called 4WPW back and canceled both orders with them! In today's world, I'm amazed how a company can screw up an order multiple times and remain in business. I told them that I wanted a full refund (including shipping charges) and that I would NEVER use them again. In the future I will stick with 4 Wheel Drive Hardware (4WHD - http://www.4wd.com). I suggest you do the same.
<RANT mode OFF>