Chapter 9: Tires, Wheels and Brakes
Chapter 10: Electrical and Lighting
Chapter 11: Recovery, Onboard Air and Trail Gear
Chapter 12: Other Useful Stuff
DEDICATION
I blame my father for all of this. He is the man who introduced a Jeep into my life when I was three years old.
ACKNOWLEDGMENTS
After many years of running a Jeep lifestyle website, jeepfan.com, I now find myself the author of a Jeep book. This lifelong obsession with the Jeep has kept me active in the Jeep community for more than 40 years. There have been so many people along the way who have tolerated my love of this vehicle and so many who have helped me grow my knowledge and ability. First and foremost is my family: my wife, Jennifer, and son, Austin, who have listened to countless hours of talk about Jeeps, many Jeep trail rides, responded to my “come hold this” requests with builds, and so much more.
My father, who truly is responsible for all of this, spent countless hours on his Jeep, which later became my first Jeep and my first build. He scared the wits out of me on the trail, took “the fam” to Jeep races, and taught me to drive the Jeep at an early age. His “learn by doing” (and making me do) approach, experience, and knowledge built the foundation I still use today. My late grandfather, whose creativity and ability to build something out of nothing, provided me with a valuable skill that is useful for Jeeps and more.
Special thanks to my favorite parts suppliers and installers who opened their doors to me: OK 4WD, Quadratec, and Jeff Daniel’s Jeep Customizations. Rausch Creek Off-Road Park, who gave some Jeepers and me the run of the place to get some beautiful pictures. ARB/Old Man Emu, Novak, TeraFlex, and Genesis Offroad for making awesome products and helping me out. Eric Jankowski for his knowledge of factory Jeep information and keeping my facts straight.
Finally, I can’t forget my close circle of Jeep friends: Ralph, Mike, Glenn, Matt, Bryan, Brian, Rich, and Mark, who always provide an opinion, advice, and a helping hand when needed.
INTRODUCTION
The Jeep line has been in production for more than 75 years and has given us many models, each with its own special qualities, but perhaps the 1972–1986 CJ series could be considered among the more special Jeeps.
The 1972–1986, or AMC era, of the CJ lineup could be viewed as the CJ at its finest. The refinements in road handling, options that improved interior comfort, and the continuation of what made the CJ the off-road vehicle it always was contributed to the creation of a legacy.
Jeep enthusiasts enjoyed an era of CJs when parts were plentiful and the aftermarket made a plethora of upgrades and accessories that could satisfy everyone. Federal and state emissions regulations were relatively light in many areas, which allowed engine performance modifications and a variety of engine swaps. In 1987, Chrysler acquired American Motors and the CJ line was discontinued; it was eventually replaced with the all-new Jeep Wrangler YJ. The off-road Jeep crowd wasn’t ready for the new toned-down Wrangler, which led to an increased interest in CJ modification.
The CJ remained a dominant vehicle on the trail well into the late 1990s but gradually faded after the introduction of the coil-sprung Wrangler TJ in 1996. Many CJs are still active in the off-road community, but most have been retired, some to rust away, and some preserved to remind us of this special era. The interest in the CJ continues today, perhaps not with the fever that it once had, but all you need to do is attend a Jeep show and look for the crowd. On the trail, the CJ still holds its own against the newer coil-spring-suspension Wranglers that have taken over the scene.
The new AMC Jeep emblem was found on Jeep vehicles after 1972. The red, white, and blue logo was so fitting of the 1970s, as America was celebrating its bicentennial.
The CJ has been used in many ways other than just getting from point A to point B. The Jeep has served well in a military capacity, as a utility vehicle, a racer, an off-roader, a movie star, and more. For the purpose of building a perfect CJ, I home in on a single category, which may stretch a bit into a few others but focuses on one goal: building and modifying a CJ for the trail. A perfect trail Jeep is one that isn’t totally purpose-built for the trail but rather built to get to the trail, run all day, and drive home. This kind of Jeep defines the true essence of what the Jeep was meant to be.
This modified 1977 CJ-7 is in its element on the trail. With minimal modification a CJ can become a considerably more capable trail Jeep from its already capable stock form.
The Jeep community continues to thrive, possibly more than ever. The introduction of the four-door Wrangler in 2007 brought a Jeep into the lives of many who would have never considered a two-door Jeep. The new interest revitalized Jeep events all over the country; events such as the Bantam Jeep Heritage Festival held annually in Butler, Pennsylvania, which has seen record attendance. The number of Jeep-related events that occur throughout the United States and the rest of the world should be enough to satisfy any Jeep fan.
The stock CJ came with so much capability right out of the box, which continues today with the Wrangler, that most Jeep owners look at their Jeep’s factory form merely as a blank canvas. A Jeep owner needs to start with only a few modifications to get his or her Jeep from stock to a well-equipped trail Jeep.
The Bantam Jeep Heritage Festival is held annually in Butler, Pennsylvania, the town considered the birthplace of the Jeep. The festival holds a Jeep Invasion, where hundreds of Jeeps parade to Butler and line Main Street to kick off a weekend of all-Jeep events.
In the following chapters, I discuss the accessories and modifications that go into building and modifying a CJ. You will learn the kind of modifications that enhance your Jeep’s performance, both on- and off-road. In addition, you’ll learn about both the ease and complexity of a build. This will help you figure out if you want to take on a build or leave it to a professional. Most of the modifications and builds I cover can be performed in a well-equipped home garage; I provide tool tips and recommendations along the way.
I’ve been building and modifying Jeeps since 1984 and have been working on a 1978 CJ-5 I refer to as “Number 5” consistently since 1997. This Jeep has seen many modifications through the years and was continually run on the trail for 10 years. It has seen many versions of lift kits, engine rebuilds, and modifications, a frame replacement, lockers, tires, wheels, etc. The list goes on and on and is still going. In 2006, I semi-retired the Jeep from regular trail use, and now it serves as a joy to drive and reminder of the capability and heritage of this era. Look for Number 5 throughout this book.
Finally, safety is the number-one concern when working on your Jeep. Don’t take chances, plan ahead, get help when needed, and be aware of your surroundings. Another word on safety is less about working on your Jeep and more about the safety of the modifications you are making; modifications often alter the way the Jeep drives. Lift kits and larger tires affect road handling and stopping