Miraz's JK CRD Build Thread - JKowners.com : Jeep Wrangler JK Forum
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post #1 of 104 Old 09-22-2010, 04:46 PM Thread Starter
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Miraz's JK CRD Build Thread

Coming up two years with my 2-dr CRD JK now, and as the modifications are about to get more serious, I thought I'd start a build thread.

Currently it has the following changes:-
- Full Set of Teraflex Control Arms
- 3.5" Lift with 700mm long travel Rancho shocks (RTI [email protected])
- Currie Anti-Rock Rear Sway Bar
- Offroad Only Pneumatic Front Sway Bar
- Original 4.1 Diff Ratios
- ARB Rear Locker
- Aussie Locker in the Front
- Chro-moly front axles + U-joints
- Front diff has been sleeved and gussetted
- ARB Front Bar + TJM Winch + Rugged Ridge HID Spotties
- ARB Compressor mounted in tailgate
- Rubicon Sill Protectors
- 35" BFG KM2 on 17" DC-1 Rims
- Custom Front and Rear drive shafts
- Rubicon Express adjustable front panhard
- Teraflex rear panhard relocation bracket



Next major change is a RockKrawler Long Arm Suspension Kit

We're blazing a bit of new ground here, as I don't believe anyone has installed the kit into a RHD JK, or a diesel....so there will be a few new problems to deal with along the way.

First problem is the installation of the control arm brackets - RK supply two hefty brackets that are bolted to the front of the transmission cross member and then welded to the frame rails - both the upper and lower front control arms attach to these brackets.

This creates a few problems:-
- The LHS bracket conflicts with the exhaust, so that needs to be modified
- The RHS bracket uses the space currently occupied by the fuel filter, so that needs to be moved.
- The bash plate that links the two brackets together doesn't provide enough clearance for the CRD exhaust where it crosses under the transmission - the sump on the 545RFE tranmission is lower, and the CRD exhaust has a greater diameter than the V6.

RHS bracket bolted into place - exhaust system removed


LHS bracket bolted into place - exhaust system removed


Played about with a few options - decided to split the exhaust into two smaller pipes to run under the transmission sump.



Not quite sure that we've left enough clearance for the drive shaft on full droop, but won't be able to tell until the new shocks are on the front.



Still working on the fuel filter, suspect it will end up on the LHS firewall, under the battery tray.
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post #2 of 104 Old 09-22-2010, 04:47 PM Thread Starter
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Still making slow progress - coilovers should go in later tonight....

Upper Arms in place, chassis rail prepped for coil over brackets


Other Side - note the new upper link mount, and that both upper arms are connected using rebuildable ball joints instead of bushes.
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post #3 of 104 Old 09-22-2010, 06:06 PM
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Southside taking some new ground on the CRD. Great to see how this all works together. Keep us informed on the final fit.
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post #4 of 104 Old 09-22-2010, 07:27 PM
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Wow, that exhaust pipe is crazy! We are taking notes along with this build. I wish we could get the CRD here in a left hand drive from the dealership. That would be sweet!

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post #5 of 104 Old 09-22-2010, 07:30 PM
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Quote:
Originally Posted by Rock Krawler Suspension View Post
Wow, that exhaust pipe is crazy! We are taking notes along with this build. I wish we could get the CRD here in a left hand drive from the dealership. That would be sweet!

Rock Krawler
Why can't you just drive up to Canada and order one?


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post #6 of 104 Old 09-22-2010, 08:14 PM
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Quote:
Originally Posted by d'sjk View Post
Why can't you just drive up to Canada and order one?
I do not think they sell Crd Jk's in Canada aye......

Jason

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post #7 of 104 Old 09-22-2010, 10:42 PM Thread Starter
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Quote:
Originally Posted by Rock Krawler Suspension View Post
Wow, that exhaust pipe is crazy! We are taking notes along with this build. I wish we could get the CRD here in a left hand drive from the dealership. That would be sweet!
Will keep you updated as it progresses.....the exhaust is an interesting problem, ended up replacing everything from the cat backwards....now looking like the RHS upper arm may conflict with the cat at full stuff, so might have to loose that too.
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post #8 of 104 Old 09-24-2010, 07:01 AM Thread Starter
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Some more progress and a few challenges....

Coilovers in place.....need longer sway bar links...maxing out the Anti-Rock at the moment.



Poly Drag link flip + panhard bracket in place - drag link seems a little short, doesn't look I can turn right at full droop



Rear End is nearly together - need to replace a broken wheel stud and get some longer brake lines

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post #9 of 104 Old 09-24-2010, 07:16 AM
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Looking good miraz seems like a lot of work
Have you seen the gen right fuel tank you can replace it at the rear and get rid of factory tank that will clear ur long arm really nice

Are the coil mounts from evo or rock krawler provided the entire kit
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post #10 of 104 Old 09-24-2010, 07:23 AM
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In the pic looks like u r using currie ant rock front and back what happened to oro sway bar
R u not going coilovers at the rear?
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post #11 of 104 Old 09-24-2010, 07:23 AM Thread Starter
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No clearance problems with the stock tank at the moment - there is only a single upper link.

Rock Krawler provided most of the kit, including the coil mounts.

Poly provided the Drag Link Flip Kit and Front Panhard Bracket

The Adjustable Panhard Rods are Rubicon Express TJ parts with different rod ends courtesy of Wooders.
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post #12 of 104 Old 09-24-2010, 07:27 AM
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Looks good!

Instead of running my exhaust(I have a Hemi) under the tranny, I had to run my exhaust on the passenger side of the tranny/TC, notching the gas tank skid a bit, and then under the CV of the rear driveshaft. The two join up under the driver seat into the muffler(mine has an X-pipe so I could run duals all the way back).

Worked out perfect & looks like it might work better for you! If you want some pictures, let me know and I'll try to find the tread for you.

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post #13 of 104 Old 09-24-2010, 07:30 AM Thread Starter
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Quote:
Originally Posted by Prope View Post
Looks good!

Instead of running my exhaust(I have a Hemi) under the tranny, I had to run my exhaust on the passenger side of the tranny/TC, notching the gas tank skid a bit, and then under the CV of the rear driveshaft. The two join up under the driver seat into the muffler(mine has an X-pipe so I could run duals all the way back).

Worked out perfect & looks like it might work better for you! If you want some pictures, let me know and I'll try to find the tread for you.
Definately interested in having a look if you still have pictures - I currently have the fuel filter tucked up into that space on the side of the tranny, but it's only a temporary home whilst I get a better solution figured out.

My main concern with the exhaust at the moment is the clearance between the RH upper arm and the down pipe with the cat in it....this picture shows what I mean


Last edited by Miraz; 09-24-2010 at 07:33 AM.
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post #14 of 104 Old 09-24-2010, 07:43 AM
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Here you go... it's tight, but I don't have any rattles and everything is tucked up out of the way much more than it was... hopefully these are clear enough for you. Oh, I used think walled 2.5" stainless for the exhaust.












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post #15 of 104 Old 09-28-2010, 07:06 PM Thread Starter
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Making progress.....it's on it's wheels now, sitting a bit higher than planned.

Sorting out wheel alignment, bump stops, etc then heading 600 miles south to www.jeepjamboree.com.au

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post #16 of 104 Old 09-28-2010, 08:18 PM
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dude

I'm super jealous right now

2-door, locked, 5.13's, 37's.
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post #17 of 104 Old 09-29-2010, 06:14 AM
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Looking good miraz ane glad ur coming to jambo

Also LOOSE those stock flares and put dbor flat fares will really look awesome with them
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post #18 of 104 Old 10-05-2010, 04:28 PM Thread Starter
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Back home after a long weekend road trip, so I have a few first impressions....

I've put over 2500km on the new setup, and I'm more than happy with the on-road handling - it soaks up bumps and rough roads like a limo, very predictable and easy to drive. Turn in is a little soft, but I put this down to the anti-rock on the front end.

Offroad - I think there is more setup work to do....the back end is working great, but I'm not getting the flex out of the front end that I expected. The whole thing feels more supple, but there is clearly something limiting the front end.

I've tried a few different configurations with and without the front anti-rock connected and something is limiting the up travel - will spend a bit of time over the weekend seeing if I can figure out what it is.

Here is a shot from a travel ramp with the front sway bar connected - notice how little up travel is available before the LH front wheel begins to lift. The bump stops are still inches away from the axle.



Flexing the other way with the sway bar disconnected - again reasonable down travel, but very limited up travel...

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post #19 of 104 Old 10-05-2010, 06:00 PM
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Are you doing the work @ Davids (Wooders garage) shop?


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post #20 of 104 Old 10-05-2010, 06:10 PM Thread Starter
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No - Wooders doesn't have any workshop facilities, so I'm working with another local 4wd specialist.

Did manage to go for a run with Bill from Double Black Offroad over the weekend though whilst I was down south...
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post #21 of 104 Old 10-05-2010, 08:43 PM
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Is the CRD lighter than the 3.8L?
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post #22 of 104 Old 10-05-2010, 08:45 PM Thread Starter
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About 80-90 lbs heavier in stock form...
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post #23 of 104 Old 10-05-2010, 08:56 PM
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Have you taken the springs off and checked where it's binding yet?
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post #24 of 104 Old 10-05-2010, 09:16 PM Thread Starter
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That's next on the list....
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post #25 of 104 Old 01-19-2011, 04:33 AM Thread Starter
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Worked out the niggles with the suspension, so now it's flexing properly at the front....the 37's don't quite clear the LOD rear bar as much as I'd like yet, so more to come from the rear end.


Time for the next stage of the build, I thought I'd have a go at building up a junkyard axle for the rear end...so I picked up a 14bolt FF axle and started rebuilding it.



Next step is to shave and plate the pumpkin to get some ground clearance back....now only 5.5" below the axle centerline.




Just waiting on a setup kit and some other parts so I can start putting it back together again...
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