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By: Mark M. DeNittis - 11/2003

What I did over my summer vacation.

There comes a time in one’s life that doing Jeep work yourself is the ONLY way to go!

As the summer faded to just a memory my school year as a Culinary Educator was about to begin. I can’t think of a better way to do an article: "What I did over my summer vacation!" I will say my Jeep project portfolio has grown considerably, although some were "farmed" out to support the local Jeep mechanic economic stimulus. Not pictured is the second rear axle rebuild... I am sure glad I paid attention the first rebuild at Moab Off Road.

Door Holder 6 Screws Free Wood and a Couple of Eye Hooks	Refresh the Faded Fenders	Hardcore Steering Linkage Upgrade

I must first start by saying I had my fair share of Jeep mechanical issues... go figure. I did not get to do quite as much wheeling as I would have preferred, which means my summer camp recipe file was not expanded upon. The most memorable moments from this summer will be my three year-old daughter’s first fishing/wheeling trips with me. She began by honing her casting skills in our driveway on her "Tigger" fishing pole. She is certainly ready to catch the first "trout-rainbow" or catfish that comes her way. She came to the conclusion (with no nudging from me of-course) that she is going to do well in school, so when she is bigger she can have a big red Jeep.

You know you have a Jeep kid when they see non-modified Jeeps and are able to point it out by saying, "That is a small Jeep. Ours is bigger, huh Dad!"

First Project (Beginning July): Dana 35 Rebuild... again!

Let me begin with the rear Dana 35 father-in-law-bonding rebuild project. July 4th weekend, Steamboat, Colorado I wasn’t even off-roading when the familiar grinding noises emitted from the rear of my TJ. The gears had burst and punctured a hole in the diff cover. All the fluid spewed out and 20 miles later my diff was smoking to say the least.

Thankfully, I watched the mechanic at Moab Off Road (2003 EJS) carefully rebuild my 35. Now with my father-in-law who has a little old school ranch ingenuity, a Haynes Jeep book and numerous tech pages printed off the Internet, we got all the parts and pieces to do a great job. My Jeep now runs better than it ever has. I still am unsure of why the gears exploded but I have my suspicions. Surprisingly the toughest part we thought we were going to encounter was getting the crush sleeve properly set on the pinon. It turned out, with some act from above, we got it on the first attempt.

Wild West Off Road and High Country 4x4, both of Englewood, CO were extremely helpful in getting me all the parts needed for the rebuild ASAP. Thanks guys!

Unfortunately I did not take pictures of the rebuild as we were on quite a time restraint. I do want to thank Four Star Automotive and Rush’s Auto Care from Steamboat for the additional tech advice, bearing press and bearing puller tool. Having all the proper tools makes life so easy.

All in all it took just over a total of four hours to complete over the course of two days.

Second Project (Mid-July): Drive shaft Replace

Thanks to the guys at Wild West Off Road in Englewood, CO again. My drive shaft was badly in need of replacement. Wild West built and installed it for a GREAT price. This completed the total rear-end rebuild project.

Third Project (Late July): Heavy-duty rear coils.

Due to sagging stock coils in the rear, tons of research, and getting the monetary initiative I finally broke down and purchased some 2-inch heavy duty Old Man Emu coils and 10mm spacers. It was a fairly easy install (4 hours) as I had done a Daystar 1 ¾-inch coil spacer lift a year prior all around. A big recommended install is a rear track bar relocating bracket. If you have fear of drilling frame metal on your rig you may want to have a shop do this, otherwise this was the most difficult part of my project. Mostly making sure all the holes were lined up properly for drilling. Also, the awkward drilling angles, getting one or two bolts to line up with the nuts can cause a few choice words to spew forth from the vocal cords. Nothing a visit to the confessional won’t cure.

Old Front: Stock height coil & double-stacked 1 ¾" spacers. I can see the low-buck guys smile.	The new front coil is a better solution.	Current Rear: OME 2" Heavy Duty coil, OME 10mm spacer, & stock rubber spacer

I used a little ingenuity to equalize the front by double stacking two 1 ¾-inch coil spacers on the front stock coils (see pictures above). So, during the summer with an additional lift height gain of just over two inches all around I was ready to go... except for the new driveline vibration and front-end "death-wobble". Bring on Project 4: the steering linkage. Double stacking is probably not recommended by most professionals in the suspension world, but it works for me for now and I have not noticed any unsafe vibrations or rolling. I am currently looking for some of that monetary initiative to buy the 2-inch heavy-duty front coils. Cut the old 1 ¾-inch coil spacers in half to use as a 1 inch spacer to end up with an overall lift of 3 inches. Confusing? Yes. Do-able? Definitely. This was finished off with a bump stop extension kit from OME and a special additional rubber piece from the original front shock mount. Really not noticeable in the picture.

I think the overall total 3-inch gain expected once completed will be a little different than those spam e-mails I keep getting. I think the increase in size will enable me to go longer and deeper for more excitement... Jeeping on the trails of course!

Christmas break is looking good for the 2-inch front coil project along with others I have planned. Also a poly transmission mount and possible 1-inch raised motor mount. This of course depends on the any newly acquired driveline vibrations that may surface after achieving the 3rd and "final" inch of lift.

You see there is a tile project, slotted for my Christmas break, in a bathroom that I will do. My wife might read this, so honey... Jeep projects weren't the only thing I planned on doing over the holiday break. ;)

Fourth Project (Late July/Early August): BEEFY (not a steak recipe) Linkage

The driveline vibrations diminished over a few days as the coils just needed to settle in. I had minor vibrations accelerating at 20-25 mph. I opted not to lower my transfer case because the vibration was minimal and I didn’t want to lose the newly acquired height gain.

On to the Death-Wobble. After a few shops told me that I needed new tie-rods and linkages ranging anywhere from one shop at $200 plus $65 for an alignment to another for $950 plus a $70 alignment I opted to again tackle this myself.

I happened to be at High-Country 4x4 in Englewood and saw just what I needed. There up on the wall in the far corner was the Currie Enterprises heavy duty steering linkage, on SALE mind you. I decided to buy it and do the install myself. Directions come with the unit and the most basic do- it-yourselfer can tackle this. The only thing I recommend, even after measuring all links carefully, spending the extra $55 bucks after install to get a proper alignment.

My favorite, of course. The 3 lb. hammer!	Loan-A-Tool Ball Joint Separator... FREE	Stouter Linkage Over Stock	Much Bigger Tie Rod Ends than Stock

Rent tools from your local auto parts store. They typically have the Loan-A-Tool program. If you don’t bring a tool back you buy it, if you do bring it back there is no charge. In other words FREE for me!

Fifth Project: Lo-Buck Door Hangers

Making more space for stuff... flipping through my magazines I see all kinds of neat stuff I could add to my Jeep... bigger axles, lockers, engine upgrades and the like... granted I had the extra money. Off-roaders by nature have a certain air of ingenuity about them. I saw an advertisement for a product to hang Jeep doors in your garage. An ingenious product... for a price! Even my wife said, "That should be an easy one to tackle!" So I went to the website for closer inspection of this door hanger for sale thingy. No immediate light bulbs flashed as to engineer this next task. Time went by and I needed something to do. I went into my garage looked around and went to work. This became the CHEAPEST and one of the better Jeep projects I have ever done.

Arrows point where to drill holes for the three-inch wall screws.	An easy BUDGET way to make more space... for more (Jeep) stuff! George Carlin would be proud.

Parts:

The three-inch screws are for mounting the units to a stud in the wall. This is a MUST. If you have one of those stud finders great. If not, here I am! Just kidding. If not, use the ole tap on the wall method: Hollow sound, no good. Solid sound, good. In a garage, usually you can see the dimples where sheet rock screws & nails are. That is usually the best indicator of where a stud will be.

I got the 2x4s for free from new houses being built across the street. Every day there were a ton of 2x4s and plywood that got thrown into a dumpster. I just asked the guys at the job site and they told me what they didn’t need anymore. Muchas gracias amigos! It helps considerably to speak Spanish, otherwise wait for the "guerro" of the site. Most of the shelving being built in my garage was from the same place. "If it’s for free, it’s for me!"

My doors now hang up out of the way until the temperatures drop below 40F degrees continuously for months on end.

Sixth Project: Fender Flare Refresh

Tape ‘em up and spray away.	I’m gonna wash that gray right outta my...

With my Jeep coming up on its seventh year of life, the flares had faded considerably, a graying of the temples if you will (a sure sign of maturity?). They were still in good condition other than being faded and I wasn’t about to dish out the money to buy new ones. Especially knowing I wouldn’t be able to get them off easily. You know... the old tire-rub-in-the-fender-well from too big a tire and no lift? A trip to the local auto parts store yielded the fix for under $15.00 dollars. I purchased a couple cans of plastic bumper spray clear primer and a couple cans of black plastic spray paint to do the job. It is kinda like that Just for Men hair care product, but for the Jeep. That was the second cheapest and easiest quick projects I had ever tackled. I recommend also using paint thinner or alcohol to prep the plastic thoroughly so the primer and paint will stick better.

Project Summary

Whatever the case may be, I did spend a good bit and save a good bit of money doing these upgrades. Internet research and good faith advice of trusted mechanics helps considerably. I have a list of other upgrades I have attempted, failed, succeeded, and learned a lot from. Too many to list and I don’t have pictures for them as earlier upgrades were pre-digital camera life. I am not ready to trade in my spatula and knives so no need to worry all of you certified mechanics. I did get to replace a mangled transmission mount that busted while out hunting, try getting up an off camber incline with a torn tranny mount. Loads of fun!

Great fishing spot at 10,000 feet elevation.	Fishing buddies: Dad and daughter

When I did get out on the trails it was to some of the most picturesque places. More importantly, it gave me a summer to remember bonding with daddy’s little girl, fishing and four wheeling.

The Jeep at Fall River	The Danger Mushroom

We also started to look for edible mushrooms such as the porcini and other varieties that can be found in the wilds of Colorado. We purchased a book for identification purposes. My daughter now knows the "danger mushroom" when she sees it. Amanita is pictured below. Although pretty, it is one that can make a person very sick if eaten.

DON’T eat ANY wild mushrooms without the proper knowledge or expert advice such as from a local mycologist society. Some varieties may cause allergic reactions resulting in DEATH!!!

Denver’s Mycology Society meets at the Botanic Gardens once a month. Check out www.cmsweb.org for more in-depth info.

Until next time... Enjoy, eat well, wheel well, and always have a "put it in four-low and get over it!" attitude... responsibly and while Treading Lightly, of course.