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Don Roy: 1993 Jeep YJ

Drive Train

This truck started as a 2.5L 4 cyl in '93. I bought it in '96 with 95,000 miles and no mods, stock. I drove it as a 4 cyl for 8 years as I built it up. The move from 33" to 35" tires finally pushed me to the engine swap in late '04 with the help of good friend Dan Shepley and other Hudson Valley 4 Wheelers club members. The swap was my mental and physical therapy while I was having Chemo treatments for 5 months.

  • GM '02 4.3L Vortec V6 engine.
  • AX-15 5-speed manual trans.
  • NP231 transfer case, with SYE.
  • Tom Wood drive shafts.
  • Ford 8.8" rear axle w/ARB and Superior Cro-Mo shafts.
  • Dana 30 front axle w/ARB and Superior Cro-Mo TJ style shafts.
  • Warn front hub manual conversion kit.
  • 5 disk brakes (5?? see photos).
  • 4.88 gears.
  • 35x12.5/15 Milestar Patagonia M/T tires. (26PSI street, 8PSI off-road)
  • 15x7 alloy wheels (I added the yellow).

Body and Suspension

From stock, the first lift was a 2.5" spring swap, then a Skyjacker 6" mono-leaf kit for a while, then a Spring Over Axle change in '06.  Currently has...

  • SOA with Rubicon Express 1.5" SOA springs.
  • Home made front bumper.
  • Olympic rear bumper (since 1997, first mod).
  • Tomkin receiver rear tow hook.
  • AtoZ Rocker Guards.
  • CJ 'Jeep' tailgate, with YJ swing and electric release.
  • Flush mounted stock tail lights.
  • Gen-Right rear corner guards.
  • Xenon Flat Fender Flares.

Extra Equipment

Almost everything on the truck has been replaced or modified, every drive train part for sure. Motor, rear axle, trans, front sheet metal, bumpers, steering box (from a '98 Durango), even the frame (due to northeast U.S. rust), have all been replaced. The only moving part with the true 195,000+ miles of the vehicle is the top half of the steering column.

  • Made my own soft top from scratch, short cab style.
  • Warn M8000 winch with synthetic rope, rebuilt in 2014.
  • York onboard air w/2.5 gal tank, air quick connect added to grill and rear.
  • Tom Woods T-Case mounted disc parking brake (4.88 x brake force!).
  • Staun automatic air-down deflators set to 8 PSI.

Interior Modifications

A lot of interior work was done over the years. The dashboard was replaced in 2010 with one from DoubleD Fab.

  • Custom flat dashboard.
  • Full Autometer gauges.
  • JVC Media Player
  • Home made console (like a Tuffy, only my way).
  • 14" Grant Gripper Series steering wheel, model 8511 (I added the yellow to the horn button!).
  • Rear seat removed long ago, so spare tire lays in rear bed when off-roading, don't carry one around town. I love my clean tailgate.
Recessed stock lights plus CJ Tailgate made to swing out. Small side socket near license plate lets Jeep tailights run off trailer.
My first Moab trip, May 2013, on 'Cliffhanger'
Gordy's Hill - Socorro, NM - Oct 2011
Home made soft top, uses roll bar as frame, small to carry.
Frame Swap day: body is on lift, frame on floor, 4.3V6 drivetrain pulled.
New home made bumper, ready to paint.
Bumper done, winch painted red when rebuilt.
Flat dash, Autometer Gauges, Grant Gripper steering wheel (with added yellow!)
Hand made fan plenum/shroud to mate new Aluminum rad to GM motor.
New swing-down skid, waiting for main plate to be welded on.
Hand made console, 16ga steel, Tuffy lock, easy stereo wiring access, locks w/stereo open or closed..
Heading to Silverton, Aug 2015. Made toneau extension for cab area while trailering with windshield down..