1994 JEEP WRANGLER ROCK CRAWLER STREET LEGAL

1994 Jeep Wrangler Sahara 4.0HO Dana 60 Atlas II NV4500

This is Jeep Wrangler built from a factory stock Sahara with a final crawl ratio of 114:1

Engine:

4.0 liter High Output, ntake replaced with K&N Filter, lways used Mobil1 synthetic and MOPAR Filters since bought used in 2004 with 160K miles, ow at197K miles.

Transmission:

Dodge NV4500 5 speed bought new in 2003 from Quadra-Tec as a kit. The Chevy input shaft and input seal supports were install on a Dodge transmission. This is a good setup and will easily mate to a Chevy V8 if decided to go this route one day. It uses a hydraulic slave cylinder and throw out bearing powered by the stock clutch master cylinder. Advanced Adapters bell housing and 4wd tail section. 10 spline Chevy input/ 29 spline Dodge output / 5.61 first gear Centerforce II Dual Friction clutch. Always filled with Royal Purple SynTorq equivalent lube. Has been changed 3 times in life of tranny. Estimate 30K miles on transmission

Transfer Case:

Atlas II bought new from Advanced Adapters, locked flat, .8 Low gear, 2 spline front/ 32 spline rear output, ual shifters modified for shortest throw and smooth operation. 1650 u-joint front/ 1650 CV rear yokes, lways filled with synthetic lube, ave two spare quarts to include. Estimate 10K miles on transfer case, ftermarket speedo drive gear to compensate for tire size and axle gear ratio.

Drive shafts:

Front is custom made by Driveshaft's of Tulsa. 20" of slip 1650 front and rear U-joints 2 ½" x .190 wall thickness, igh tensile strength steel as a hydraulic cylinder was used for the driveshaft material. Balanced and true. Rear is also custom made by Driveshaft's of Tulsa. 8" of slip 1650 front U-joint/ 1650 rear CV joint Same as front but 3 1/8" OD x .190 wall thickness, igh tensile strength steel as a hydraulic cylinder was used for the driveshaft material. Balanced and true. So far the rocks have not been able to damage these shafts and I have dropped and banged the full weight several times against them, have been very happy with them. Drive shafts can very easily be the bane of any serious off roader and these have served me well.

Suspension:

Front and rear custom leaf packs, pring over on custom anti-wrap perches and 5/8" U-bolts.

Rear has a custom anti-wrap bar with double Johnny Joints at the pivot. Very mild anti-squat felt when loaded. No sway or panhard bars used. Wheel base stretched 8" overall, ront shackle reversal and all shackles 3/8" plate, rease able bolts and polyurethane bushings. New Front KG Shocks, ll shocks were tested for and all in working order.'

Front Axle:

Dana 60 High Pinion from 78 F-250, ing pin with high clearance arms and 1.5" x .25 wall tie rod and drag link. 7/8" SS one piece FK rod ends throughout steering linkages. 5.38 gears Detroit Locker 35 spline 1.5" 4340 chrome-moly inner and outer shafts purchased from Yukon gear. Inners and Outers are USA made. No twisting in either so far and I broke the stock long side inner once before upgrading to the new ones. Warn premium 35 spline lockout hubs installed with spare set included. One hub in the spare set was damaged and can be sent to Warn for replacement, ifetime warrantied. Converted to vented disc rotors and ¾ ton calipers, eavy duty stainless steel extended brake lines added with custom mounting. 8 x 6.5" hub bolt pattern with 9/16" wheel studs and zinc plated heavy lug nuts. This brake setup is based on a custom bracket, ery stout and will clear 15" steel rims with 5" of BS. The outside width with current tires at 6 psi is 86" and WMS of 69.5"Always used Royal Purple 80/90W and changed lube 2 times since axles were built. Heavy duty ¼" plate welded differential cover with low clearance socket head cap screws 1650 high clearance pinion yoke.

Rear Axle:

Dana 60 HD from 86 E-350, D has a smooth outside casting with all ribs internal, ery strong housing and glides over rocks. 5.38 gears Detroit Locker 35 spline 1.5" 4340 chrome-moly Moser axle shafts, ustom grind but each side is the same length. Axle was widened 3" to match front width; this is why I chose a van axle for the offset differential. Converted to vented disc rotors and ¾ ton calipers, ounted on custom welded brackets. No parking brake so less to maintain and fail. 8 x 6.5" hub bolt pattern with 9/16" wheel studs and zinc plated heavy lug nuts. This brake setup will also clear 15" steel rims with 5" of BS. The outside width with current tires at 6 psi is 86" and WMS of 69.5" Heavy duty ¼" plate welded differential cover with low clearance socket head cap screws 1650 high clearance pinion yoke.

Wheels and tires:

Super Swamper TSL SX II's 42 x 16 x 15 Bias plies with 75% tread 2 years old. Allied Rockathon steel Beadlocks, 5 x 10 with 5" BS 32 bolt style. I balance my tires with 22 ounces of premium airsoft pellets; I think these are 30 gram size.

Extras:

36" Cree LED light Bar 15k lumens Spare 40" super swamper LTB, nly carry on long trips and I have never needed it. Swing out jerry can holder, ncludes 5 gallon fuel and 5 gallon water jugs, teel. Also I custom mounted a Halon fire extinguisher between them, ustom center console from ammo can

Racing lap belts, impson 5 point but only use 2 points for comfort, enwood deck, aterproof, o CD function, ompatible with USB and iPhone/iPod devices and has storage behind faceplate. 11 CFM York air compressor mounted and wired, orks well but no reservoir in system, ave one to mount though.

Warn HS9500 winch with 3/8" x 100' X-Line high temp rated synthetic line and heavy duty aluminum fairlead. One of my favorite upgrades, inching up a steep section is a ton easier with rope since it doesn't bind and grind like cable tends to. GenRight aluminum fuel cell and 3/16" skid plate. Holds 15 gallons and uses the stock sending unit.