My 1977 CJ7 Restoration-Modification Project

Thanks for all the great info!!!! How long has it taken you to build your machine? If an AMC 20 was properly trussed, tubes spot welded to the pumpkin, and quality 1 piece axles installed, do you think it would hold up to 400 hp? You've got 37's, wow!!! What's your axle ratio? Haven't had time to investigate, I believe I have wide track axles, haven't taken the time to measure.

 

Been following this post. Man, you guys know your shit. I've followed a build or two by OFFGRID. Now between the two of you. Jeep build ( sensory) overload.. Awesome thread guys. Enjoying following it. more.

 

They put the AMC20 in the full size J20 with the 360cid. I believe it will control the 400. I have 456 gears. Took me almost 2 years to build it the first time. I started wheeling it and found out my frame was rotten from the inside out. Ordered a TDK frame. That swap took me 3 months. I have been making changes here and there since. Have a Dana 44 for the front in the garage. My next project will be to build it and make it fit hopefully without outboarding the springs. When I do that I will likely extend my frame 10 inches in the front and add full Hydro steering. Extending the front will move my center of gravity closer to the middle of the jeep, allow me to keep the gas tank in the OEM location, and with my rear axle currently moved back 2in give me 103in wheel base.

 

You make a valid point with regards to the AMC 20. I support the acronym "J E E P": "Just empty each & every pocket". When you extend your frame, you'll have the platform for a CJ6+. I thought I'd been through the valley with terrible discoveries (frame rot), that's what got me here to begin with. You really do have a purpose-built trail rig. I don't know how far I'll get with my project between now and January, but I'll keep updating my thread. Winter is slowly creeping up on us. I think I'll build a clear plastic tent inside my garage to help contain heat from a couple of small electric heaters. My Lokar shifter, Mr Gasket radiator cap, and Flex-a-lite transmission cooler came in. Today, my Flex-a-lite aluminum radiator/electric fan combo is due to arrive. I'll try to post more photos this evening.

Many thanks JKBob!!!! Wish this project could accelerate itself. Lol

 

I really like the look of my Lokar shifter. It has an old school look and feel, but it is really hard to use. One of the things on my list of things to do is see if I can modify it to get a quick shift to reverse. If I ever start tipping back there is no way I can get it to reverse in time to prevent a rear roll over. Check out this article on gear shifter modification:

http://www.billavista.com/tech/Articles/Ultimate_Offroad_Auto_Shifter/index.html

 

If you are going to do your own regearing, this is a must read. Be warned that I spent close to $1000 on special tools required to do this job right and that was with a lot of shopping around. I'm building my second set of axles now and I am glad I made the investment in tools and learning. Also if you are going to use the AMC, you might look into RaTech's AMC20 crush sleeve eliminator.

http://www.billavista.com/tech/Articles/Gear_Setup_Bible/index.html

http://www.ratechmfg.com/amc.htm

 

Thanks for all the great links, very informative!. Axle work is beyond my scope and my rock crawling days are over. I don't have the nerves. I like jeep trails, just not that extreme. My rig probably will not get that much off road use. I wouldn't mind taking it to the mud bog, since I don't have to travel far for those venues. They're very popular here in eastern NC. I am hoping 4.10 gears with 35's will be adequate for trails, mud and highway.

 

Here's a quick update, and a couple of photos. First off, without any reservations, the NP205 will be replaced by my Dana 300. There's barely 9 inches of clearance between the bottom of the NP205 and my garage floor (I thought it was 10"). The upper welded cross brace that supports the TH350 is bolted from the top of the transmission. That will be removed and I will install the original cross member/skid plate. I've got get busy and start removing the body parts from the old chassis and order more parts.

 

Here's a better pic of the current transmission mount.

 

When you install the Dana 300 and new cross members shoot some pics and show us how everything comes together.

 

Will do!!! I've been busy prepping for incoming family & Thanksgiving. I'll be ordering the D300 rebuild kit and twin stick kit from JB Custom Fabrication. and the TH350 to D300 adapter will come from Novak adapters. I'll be submitting my order after Thanksgiving. I'm going to start removing the TC and tranny Friday. Depending how long that takes, maybe I can start removing the body parts on Saturday. Happy Thanksgiving everyone!!!

 

In case you don't like where the shifters are located you can get cable shifters for it. Something like this:

https://www.ebay.com/i/351314895076?chn=ps&dispctrl=1

 

Thanks Offgrid for the tip. That's actually a good idea, but I think I should be able to install the traditional lever twin sticks. ***NEWS FLASH!!! If Murphy's Law doesn't strike, I've setup a horse trade deal to which, I'll be the proud owner of a matching axle set wide track Dana 44 rear with it's associated partner, (I believe Dana 30) front axle. They came out of a 1986 CJ7 that had a dash fire. Hope these will be a good foundation to compete my drivetrain. Brand new axles are too much for me to spend right now. I was told the Dana 44 from an '86 CJ7 rear was the "holy grail" of Jeep axles. I don't know how true that is, but after pricing parts for the AMC 20, to include one piece axles, bearings, shims, crush sleeves, 1 inch stitch welds for the tubes, axle truss, welding the axle truss, etc; I thought it would be a better investment, to rebuild the Dana 44. I've located parts that are "suppose to be" heavier duty than the stock Jeep D44. I will research so more and update y'all with my data. I really am thrilled to locate the '86 D44 matching set of axles. Now, about $4k more to spend in parts and labor versus $8k for new front and rear. Hope everyone had a nice Thanksgiving. Personally, I'm not that crazy about turkey.

 

Love this project, good luck!!

 

Still haven't received my Flex-a-lite electric fan/aluminum radiator yet from Autozone, it's suppose to arrive next week. All other parts have been ordered. The "tear-down", transformation starts today. I've never disassembled a CJ body before, this should be interesting. I'm going to start with the front, and work my way to the tub. We'll see how many weekends this takes.

 

For those experienced gear ratio gurus, I've got a question. While researching master rebuild kits for axles and ring and pinion gear sets, I've noticed I'm limited on choices. I've narrowed it down to (2). Either 3.73's or 4.09's. Since the tranny is a TH350, 3 spd (no overdrive), and I'm pretty firm on 35" tires, which is more desirable for a daily driver? Nope, I will not do rock crawling. Primarily pavement, a little mud and sand.

 

Great find on those axles. 4.10s for sure on the gear ratio. My buddy ran 4.10s on his with 33s, and now 36s. He tranny is a stick. I have 4.56 with 37s and a TH350. Wish I had a torque converter lockout on the highway. Yours won't be as bad as mine with the 4.10s and 35s.

 

Just found out the axle set I'm getting has 2.73:1 ratio. According to jeeptech.com, in 1986 you were limited to either 3.31 or 2.73:1 ratios. I can't imagine the acceleration (unless it was a 4 or 6 cylinder engine). I'm still kinda' "on the fence" in my decision making. A friend of my stepson just sold his '80's CJ7, he had a GM383 stroker motor in it, TH350 tranny, unknown TC, and 4.10 gears. He was running 37 inch tires and turning 2800 rpm at 55 mph. I looked at Randy's ring and pinion RPM calculator, but it's not accurate for a non-overdrive tranny. I've got to do some more digging. My CJ might turn out to be a pavement princess after all. I don't think it would be too often that I would drive it at 60-70 mph, but I'd like to have the option available.

 

That speedo had to be off. With my CJ 456 gears and 37s I am about 2800 and 65-70mph. I havent run the th350 on the freeway yet, but I expect it to run a little higher rpms to get to 70. Maybe 3000.

 

I haven't made my mind up yet on the gear ratio. As of yet, I've got bigger fish to fry before making that choice. Like I said in my opening thread, my knees are shot, like needing surgery. I'm considering reconfiguring the suspension to near stock. Currently, it has a spring over setup, with worn out 33" tires. To make ingress and egress easier, I believe it to be easier to utilize a lower stance, at least until I've fully recovered from surgery. If I temporarily use the stock 2.73 gears and 31" tires and.....with the engine/tranny that I have, I know my CJ7 will be a sluggish performer but hopefully functional. To update everyone, parts have been slowly arriving. So far, I have the Lokar floor mounted shifter, TH350 master rebuild kit, high performance sprag, and transmission case savers. Tomorrow, my D300 master rebuild kit and twin stick kit is due to arrive. I've begun removing the body parts from the old CJ7, and I removed the NP205 from the "Franken-Jeep". Photos to follow. Hope I can prevent the duplicate images this time.