Summer Jeep Build - Part 2

To start this build I decided that I was going to seal up the half cab and apply another coat of bedliner. Then just leave it to dry while I worked on the underside of the Jeep.

Before:



After:



Since I have the swing away tire carrier there really isn't a need for a tailgate. Eventually I will build a simple metal screen off the swing away that takes the place of the tailgate. After reading through several online write-ups on SYE installations, I decided that I was going to pull my transfer case, install the SYE, fill with oil, and replace under the Jeep. Side note: if you are doing this by yourself, make sure you have a transmission jack or decent bench pressing skills. Since I do not have a cool jack I used a crush box when removing the t-case (a box filled with packing supplies). I just pulled off the case and had the box absorb the weight of the fall.



On the desktop ready for disassembly.



My gear puller has a 5" reach. My harmonic balencer exceeds that. I lost patience.

Removed the tail housing.

The old shaft.

New guts!

Buttoned up with new tail housing. I thought I would be easier to leave the rear yoke off and put it in position when I installed the new rear drive shaft. I was wrong. The yoke forms a seal in the rear that is necessary to keep the oil in the housing. It dumped on me as soon as I had it on my chest ready to lift into place.

Fully installed with the new CV shaft. Might have to get a custom one made after the lift goes on, we'll see what happens at full droop. 

Since I am still waiting on Fox to build my shocks, I decided to knock out as much of the lift install as possible. As soon as I got done with the SYE I installed the lower control arm mounting brackets, welded them, and then installed the new skid plate.



Welds are cleaning up! This is a shot from the tire mount I've been working on.



Continued - Part 3