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Ultimate Adventure 2007 Jeep Wrangler JK - UAJK

2007 Ua Jeep Wranger Jk Discussion

2007 Ua Jeep Wranger Jk Laptop

2007 Ua Jeep Wranger Jk Front Suspension
Our front suspension is a mixture of stock Dodge Mega Cab front coils with shocks and Rockrunner link arms from Superlift suspension. The tubular Rockrunner links are adjustable for caster and suspension tweaking if need be, while the Dodge coils provide plenty of support for the 1,100-plus-pound engine, yet keep the whole Jeep low for stable performance off road.
2007 Ua Jeep Wranger Jk Leaf Springs
In the rear we kept the Dodge Mega Cab leaf springs but removed the factory blocks and some of the overload springs. We found that this made for a nice soft pack, but we eventually added a custom Superlift add-a-leaf for a bit more rearend support. Tune in next month to see the special Torque Fork Superlift built to help deal with any axlewrap from our big torque diesel.
2007 Ua Jeep Wranger Jk Fuel Tank
The Jeep JK uses a long tank that runs down the passenger-side framerail, however the Dodge frame we used is slightly narrower and the passenger side is reserved for the diesel exhaust. Lo and behold, a Jeep TJ rear fuel tank fit quite well behind the rear axle. The Jeep JK has a deep pan in the rear of the tub for storage, but we simply cut that out and stuffed the tank up under the rear bed of the Jeep. Even more amazing was how the in-tank fuel pump from the diesel Mega Cab seated in the TJ tank almost perfectly.
2007 Ua Jeep Wranger Jk Engine Gearboxes
After the frame was finish-welded and painted, we dropped the engine and gearboxes into the shortened Dodge frame. Note the cable shifters for the Atlas transfer case to easily shift from high range into 3.8 low. The Atlas from Advance Adapters has become the benchmark in aftermarket transfer cases and we have yet to be disappointed in any we've installed. They're designed originally as a beefed-up Dana 300, and we have run them behind big-blocks and with up to 49-inch-tall tires.
2007 Ua Jeep Wranger Jk Driveshafts
Running from the Atlas to the Power Wagon axles is a set of driveshafts from JE Reel. The driveshafts are just 2 inches in diameter to help keep them clear of rocks, but they are made of 0.120-wall tubing for strength. We used 1350 series U-joints at the Atlas and front pinion, while the rear Power Wagon 10 1/2-inch axle uses a flange to a 1410 U-joint. By the way, that rear axle is similar in size to a GM Corporate 14-bolt with 30-spline 1 1/2-inch full-floating axleshafts, but like the front it is fitted with the AAM electronic selectable locker.
2007 Ua Jeep Wranger Jk Exhaust
A Cummins diesel is not the quietest powerplant, and with the turbo and exhaust running right next to the passenger's feet, we opted for some quality heat and noise insulation. The turbo was wrapped in a heatshield and the first few feet of exhaust were also wrapped in exhaust wrap, both from HeatShield Products. Additionally the firewall was covered in adhesive-backed heatshield mat also from HeatShield Products to keep noise and high engine temperatures away from the occupants in the Jeep.
2007 Ua Jeep Wranger Jk Engine
One of the major hurdles was getting the Cummins 24-valve common-rail diesel engine to run properly. Since it arrived with an automatic transmission behind it, we needed to purchase a new computer that was then programmed with the manual transmission parameters. If you don't have the skills or funds to take on a project like this, but you still want to swap in a big diesel, we might suggest looking at early 12-valve Cummins diesels that can be run with as few as three wires.
2007 Ua Jeep Wranger Jk Brakes
In addition to making the Jeep run, we also needed a way to make it stop. The Wrangler comes with a standard brake booster powered by engine vacuum. However the diesel Mega Cab is outfitted with a hydro-boost system where the brakes are powered off of the power-steering pump since diesel engines do not offer the vacuum required for proper braking. We looked into aftermarket vacuum pumps, but decided instead to graft the Dodge hydroboost onto the Jeep firewall, as well as integrate the factory antilock brakes. The resulting brake system with the Dodge Power Wagon discs at all four corners was excellent, even with big tires.
2007 Ua Jeep Wranger Jk Wheel
And so with the engine wired and brakes and fuel plumbed, we finally had a chance to crank over the oil-burning beast under the hood of our JK. Unfortunately there is still much more work to show, like the custom Griffin radiator and intercooler, but not enough space this month to show it. Tune in again in 30 days when we cover the Fab Fours Jeep bumpers we attached to the Dodge frame, the fresh coat of 60-year-old paint, and all the little things like bead locks, winch, seats, and safety gear. Plus we'll show you how we made these prototype 42-inch BFGoodrich Mud-Terrains fit on our Jeep while keeping it the same height as your average lifted Wrangler on 37s.

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