Esrgw 3

MARCH 2020 VOL. 43, NO.
62 COVER SECTION
E-Z DRIVEWAY INSTALLS
22 FRESH FLUID
DIY auto transmission flush.
26 ARMOR UP!
Quick and easy body protection for a CJ-7.
30 DASH REHASH
Make an old truck feel a bit newer.
36 BRAKE UPGRADE
Bigger brakes for a Jeep JK Wrangler.
42 QUICK COOL
Quick transmission cooler install.
44 DRIVEWAY EFI UPGRADE
Fuel injection and ignition upgrades
for older vehicles.
48 AUTOMATIC STEPPER UPPERS
Electronically operated step installed
44 22
on a JL Wrangler.
60 AUTOMATIC SHIFTER
Electronic sport mode shifter.
TECHNICAL
32 CHEVY VORTECH 454
Reviving the engine in a “free” truck.
50 ARE FULL-WIDTH AXLES FOR YOU?
And how wide is too wide?
58 HILLBILLY CRANE
Engine hoist becomes yard crane.
FEATURES
14 BEST OF SEMA: PRODUCTS
The new off-road parts that turned our head.
38 NEVER ENDING CANYON
4x4 buggies on a birthday romp.
54 TACOVERLANDER
2012 Toyota Tacoma suited up
for overlanding.
62 SLICKROCK TRAIL
Amazing scenery and exceptional
campsites.
38 66 RESCUING RAYMOND
Road trip in a big green Ford.
DEPARTMENTS ON THE COVER: Well, this is awkward. Our

illustrious tactical cameraman, Harry Wag-
4 4XFORWARD 70 NEW PRODUCTS ner, snapped an awesome shot of this killer
2006 TJ Wrangler Unlimited owned by—wait
6 READERS’ RIDES 72 NUTS & BOLTS
for it—Harry Wagner. Our 4WOR freelancer,
8 DRIVELINES 74 WHOOPS! Brian Sumner, was piloting Harry’s “pretty
Jeep” through the Slickrock Trail while Harry
guzzled gas in his 1977 F-150, Raymond.
COPYRIGHT 2019 BY TEN: PUBLISHING MEDIA, LLC. ALL RIGHTS RESERVED.
BY Christian Hazel
EDITOR@4WOR.COM
VISITING REAGAN’S RANCHO DEL CIELO
I
’VE SEEN THE SUN RISE AND SET us to view what is in essence a very fru- the workhorse called to duty, with Reagan
over the Australian outback 200 gal, down-to-earth home, much like the in the driver’s seat throttling the F-head
miles from any manmade struc- person who owned it. Want examples? 134 four-cylinder and toggling the T-90
ture. I’ve driven multimillion-dollar Because Reagan’s frame was longer than and Spicer 18 gearboxes himself.
prototypes that most people will the bed he slept in, he used a bench to I hopped in the driver’s seat and Don
never even see in person. I’ve had support his feet where they hung past the pushed the Jeep out into the open air so
dinner with the presidents of car edge of the bed. Yup, the most powerful we could give it a proper once-over. The VIN
companies. I’ve driven some of the sick- person in the free world made due with verified it was a 1962 model. Some body-
est 4x4s while leading the world’s most an old bed that most likely conveyed with work and a repaint in the same maroon
prominent off-road event. And I’ve sat the purchase of the ranch. Reagan laid color as when Reagan owned it had been
at the helm of the three largest off-road down the linoleum tile flooring himself. All done, but the factory Foam Green hue was
media brands in the world. But if I had to the kitchen appliances were Harvest Gold still visible underneath the toolbox lid and
choose one single thing that stands out units he got when he was a spokesman in areas of the firewall where the repaint
in my 20-year career it would have to be for General Electric. There was one single had chipped away. (Just saying, my Project
getting the opportunity to visit Ronald television set in the living room. The Gip- Hatari! and UACJ-6D project Jeeps were
and Nancy Reagan’s Rancho del Cielo to per’s Stetson hats and riding pants hung both a very similar color.) You could still dis-
inspect Reagan’s 1962 CJ-6. not in a fancy closet or armoire but on tinguish bumps and bangs that the post-
The funny thing is, I didn’t even set it up. open shelving outside the bath. In short: Presidential respray didn’t completely hide,
My buddy, Don Allen, made all the requisite modest, comfortable, and approachable, and of course the side-saddle rear utility
calls and did all the legwork. At the time I much like the President himself. seats were still there with the same tears in
was the tech editor of Jp magazine and just After touring the house we were led the cushions as you can see when Reagan
strolled up to the front office of the Young outside to Reagan’s tack barn, where he’d was piloting it.
America’s Foundation (yaf.org) in Santa often saddle his horses himself. Parked No, I didn’t actually get to drive it because
Barbara, California. After being allowed inside was the President’s Subaru Brat, a we couldn’t fire the long-dormant engine
behind the velvet rope to get some up-close Cub Cadet riding mower complete with without a lot of precautionary preparations
photography of Reagan’s CJ-8, I was loaded the Presidential seal, and the often- the YAF wasn’t prepared for yet, but I did
into a Grand Cherokee and whisked up the photographed, ubiquitous CJ-6 that the get to sit, steer, and brake like the Gipper.
I-5 to Refugio Road to climb the long, windy President used himself to maintain the And considering I voted for him in my Sec-
grade to the gates of Rancho del Cielo. ranch. Whether limbing low-hanging ond Grade presidential election in 1980,
A representative from the Young oak trees so they wouldn’t be a danger that’s pretty cool. Yeah, I’ve had an exciting
America’s Foundation escorted Don and to people on horseback, building picket career, but that’s one professional experi-
me through the ranch house and allowed fencing, or clearing brush, the CJ-6 was ence I wouldn’t trade for any of the others.
4 MARCH 2020 4-WHEEL & OFF-ROAD 4WHEELOFFROAD.COM
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COMPILED BY Tom Morr
READERSRIDES@4WOR.COM
HIGH-COUNTRY TOY
VEHICLE: 2016 Toyota Tacoma OWNER:
Doug Gosh, Denver, CO TIRES & WHEELS:
35x12.50R18 Cooper Discoverer STT Pro,
18x8 alloy SUSPENSION: Toytec 6-inch lift,
Boss 2.5 front coilovers, 2.5 remote-resi
rear shocks DRIVETRAIN: Stock PERFOR-
MANCE: Borla exhaust OTHER MODS: Insain
Fab bumpers, Baja Designs lights DOES IT
WORK THE WAY YOU WANT?: Yes, it does
great off-road
VINTAGE TUXEDO PARK
VEHICLE: 1965 Jeep CJ5 Tuxedo Park
UNLIMITED OWNER: Jason Miller, East Berlin, PA TIRES &

WHEELS: 30x9.50R15 BFGoodrich KM3, stock
JK FUN 15x5.5 repainted wheels SUSPENSION: Stock
VEHICLE: 2015 Jeep leaves, new Omix-ADA shocks DRIVETRAIN:
JK Wrangler Unlimited T-90 transmission, Spicer 18 single-stick
Sport OWNERS: Rex T-case, Dana 27 front axle, Dana 44 rear axle,
& Mary Willis, Apple 4.27 gears PERFORMANCE: Stock 134ci
Valley, CA TIRES & F-head with a good tune-up, new Solex car-
WHEELS: 37x12.50R17 buretor OTHER MODS: 7,500-pound winch,
BFGoodrich KO2, 17x9 off-road cube lights, Hi-Lift jack mounted to
Pro Comp Vertigo roll bar DOES IT WORK THE WAY YOU WANT?:
SUSPENSION: Rubicon Yes, finally got it trustworthy on the road and
Express 31⁄2 -inch Super back in the boonies ANYTHING YOU WOULD
Flex kit, Fox 2.0 res- CHANGE?: Frame is solid but it needs a new
ervoir shocks DRIVE- tub. Will save that for when my two boys
TRAIN: 3.6L V-6, Dana (2 and 4) are a little older, and we’ll do that
44 axles with Yukon chromoly axleshafts, E-Lockers, Power Stop brakes, 4.88 gears OTHER together. FUNNIEST WHEELING INCIDENT:
MODS: Smittybilt Rock Sliders, Atlas rear bumper, XRC front bumper, LED rock lights, sPod switch Letting my little guys “drive” the Jeep on my
panels, Alpine/Kicker sound system DOES IT WORK THE WAY YOU WANT?: Absolutely! It really lap back in the fields on our property, seeing
provides a nice balance of off-road and on-road capabilities, but allows us to enjoy an extended their faces light up in the Jeep, makes me look
weekend of exploring without having to trailer. ANYTHING TO ADD?: We’re looking into a hood forward to the years to come off-roading and
upgrade, inner fender liners, and onboard air. Planning to do the Rubicon this summer. We really going camping as a family, something we are
enjoy the time together and look forward to the next trail that awaits. missing in today’s society
SUBMISSION INFORMATION
Send us a picture of your ride if you’ve
never done so. We keep a surplus of Read-
ers’ Rides submissions, but only one sub-
mission per person, and we love all off-road
vehicles so send in your entries whether
your rig is stock or not. Make sure each digi-
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WRITE TO: Readers’ Rides, 4-Wheel &
Off-Road, 831 S. Douglas St., El Segundo,
CA 90245
EMAIL TO: readersrides@4wor.com
> VEHICLE (year, make, model)

> OWNER (name, city, state)
> TIRES & WHEELS (size, make, model)
> SUSPENSION (lift, springs, shocks) LINED-OUT BRONCO
> DRIVETRAIN (tranny, transfer case, axles) VEHICLE: 1994 Ford Bronco XLT OWNER: Rory Beatty, Clarkdale, AZ TIRES & WHEELS: 35-inch
> PERFORMANCE (engine mods) Dick Cepek Extreme Country, Moto Metal 951 with custom paint SUSPENSION: Pro Comp 4-inch,
> OTHER MODS Rancho shocks DRIVETRAIN: E4OD transmission, BW1356 T-case, Super Duty Dana 50 front
> DOES IT WORK THE WAY YOU WANT? axle, Sterling 10½-inch rear axle with disc brakes, 4.56 gears PERFORMANCE: 5.8L V-8, ported
> ANYTHING YOU WOULD CHANGE? heads, Lunati roller cam and valve springs, 3-inch Y-pipe, MagnaFlow mufflers OTHER MODS:
> FUNNIEST WHEELING INCIDENT Home-built bumpers, Superwinch 9500 winch, Corbeau bucket seats, Tuffy center console
> ANYTHING TO ADD? ANYTHING TO ADD?: Love this Bronco, it has Line-X in and out so it laughs off all of the Arizona
pinstripes and is amazing on the trails
Unforgettable Adventures.
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Heed the call of adventure with great insurance coverage.
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BY Drew Hardin
EDITOR@4WOR.COM
2021 COLORADO GOES DESERT RACING
C
hevrolet unveiled the 2021 Colorado—
sporting a new look—at the Best in the
Desert Method Race Wheels Laughlin
Desert Classic in October, alongside a
competition version that’s part of the
Hall Racing team.
Chevy says the entire 2021 Colorado lineup will get greater
differentiation from trim level to trim level. For example, the ZR2
seen here will be the only model with the lettered, flow-through
“Chevrolet” front fascia. WT, LT, and Z71 trim levels all receive
updated center bars, lower fasciae, and front skidplates for 2021.
WT and LT will feature an all-new gold Chevy bowtie logo, while
Z71 receives a black bowtie logo.
Chevrolet and the Hall Racing team have been racing the ZR2
since 2017. Their experience in the desert has led to the develop-
ment of 15 ZR2 race parts available through Chevrolet Perfor-
mance. The facelifted truck got off to a good start at Laughlin,
where Chad Hall drove the Colorado to a First in class, though he
was the only entrant in the class. Still, the Hall Racing team has
learned how to keep the Colorado alive in the brutal Best in the
Desert series, earning the distinction of being one of only four of
434 vehicles to finish all 12 Best in the Desert races it competed
in since it started racing.
“ Colorado gets a new look for 2021
”
THIS
starting MSRP of $125,000. U.S.-
based production will start in
JUST IN
2020, with deliveries beginning
in 2021. The company is accept-
ing $1,000 refundable deposits
• RUMORS ARE CIRCULATING at bollingermotors.com/reserve.

that Chevrolet may be prepping
a version of the Silverado that’s
• BEST IN THE DESERT CROWNED
its 2019 season champions fol-
even more off-road capable lowing its final race of the year,
than the current Trail Boss. the Method Race Wheels Laughlin
Recent photos of a prototype Desert Classic. Jeff Terzo was the
truck published by SEMA seem Trick Truck champion, while Jeep-
to bolster the validity of the Speed champs included Bob Seu-
rumor. Called ZRX, the pickup is bert (Class 1700), Robert Thom-
rumored to have a more robust asson (3700), and Billy Bunch
suspension than the Trail Boss (4700). The year-end Ford Long
with Multimatic DSSV shocks, Haul award, for the car/truck team
electronic lockers front and rear, with Ford support trucks that had
and shorter bumpers to improve the lowest total elapsed time of
the truck’s approach and depar- the year, went to Steve Olliges.
ture angles. The mule in SEMA’s
photos does have an abbrevi- • RYAN ARCIERO WAS FIRST
overall and the Trophy Truck class
ated front bumper, accessorized winner at the inaugural Lucerna
by what looks like a combo SCORE Baja 400. Arciero, driving
brushguard/skidplate. The truck his Levi Arciero Racing Ford F-150
also has a healthy ride height built by Herbst-Smith Fabrication,
over aggressively lugged tires. covered the “intensely rugged”
SEMA also reports that GM has (per SCORE) 390-mile course in 8
trademarked the ZRX name, add- hours 26 minutes 32 seconds, for
ing credibility to the rumor. an average speed of 46.20 mph.
• LAST MONTH WE TOLD YOU
about the advances Bollinger
“Everything was smooth for us
today, and the new Joe Gibbs Rac-
Motors is making with its all- ing motor was sensational,” said
electric B1 SUV and B2 pickup Arciero. “Great power, and we have
models. Bollinger recently NASCAR guys in off-road, which is
announced that each will have a a super crossover in the sport.”
…AND SO DOES SILVERADO
A
few days after the Colorado ZR2 announcement, Chevrolet said its big brother
Silverado will also compete in the Best in the Desert race series as another vehi-
cle in the Hall Racing stable. Like the Colorado, it finished First in its class (of one)
at the 2019 Laughlin Desert Classic.
The Silverado, which started life as a LT Trail Boss model, competes in the 1200
Stock class, which limits racing modifications to the suspension, underbody, and
installation of race-safety equipment. Hall Racing fitted the truck with a long-travel
suspension, front and rear jounce shocks, and prototype high-capacity Multimatic
DSSV dampers, which were scaled up from the DSSVs used aboard the Colorado.
4WHEELOFFROAD.COM 4-WHEEL & OFF-ROAD MARCH 2020 9

DRIVELINES
EARTH
was largest in Hawaii, Montana,
Maine, Vermont, and Wyoming.
•
WATCH
RAM RELEASED EPA FUEL
economy ratings for 2020 1500
pickups equipped with the
• SEMA REPORTS THAT FOR

the second consecutive year,
EcoDiesel V-6 engine option: 32
highway/22 city/26 combined
federal government statistics for 4x2 models, 29/21/24 for
demonstrated that outdoor 4x4s. That compares with
recreation is a key driver of the 24/19/22 for a 4x4 Ram with the
national economy and com- V-6 eTorque (mild hybrid) engine,
munities around the country. 22/17/19 for a 4x4 with the
The U.S. Bureau of Economic eTorque Hemi, and 21/15/17 for a
Analysis (BEA) report found 4x4 with the conventional Hemi.
that outdoor recreation in 2017
supported 5.2 million jobs and
• CALIFORNIA GOVERNOR
Gavin Newsom signed into law
accounted for $778 billion SEMA-supported legislation (SB
in annual economic impact. 112) that immediately restores
Some of the largest outdoor fix-it tickets for cars suspected
recreation activities include of violating the state’s exhaust
EXTREME MILITARY GRADE GLADIATOR
A
motorized recreation, boating noise limit and allows car own-
and fishing, RV’ing, biking, hunt-
M General and FCA are collaborating to produce a light tactical
ers 30 days to correct viola-
ing, camping, and skiing. The tions. SB 112 amends a 2018 concept vehicle based on the Gladiator pickup. The Gladiator
BEA’s report notes outdoor rec- law (AB 1824) that removed Extreme Military Grade Truck (XMT), which was unveiled at the
reation makes up 2.2 percent this ability and generated sig- Annual Meeting and Exposition of the Association of the U.S. Army,
of the country’s gross domestic nificant concern within the spe- has been upfitted by AM General “with both custom-built and com-
product, which is larger than cialty automotive aftermarket mercially available military-grade parts to create an even more
many other industries, such as industry and enthusiast com- rugged truck that can traverse the toughest of terrains in adverse
mining, utilities, farming and munity. Since 2003, exhaust conditions and is ready to meet varied military customer require-
ranching, and chemical prod- systems installed on motor ments,” says the company.
ucts manufacturing. For the first vehicles in California with a
As it did with the Humvee, AM General can “convert the Gladiator
time, the report also compiles manufacturer’s gross vehicle
economic data for the 50 states weight rating of less than 6,000
XMT into mission-specific lightweight tactical trucks based on cus-
and District of Columbia. Cali- pounds, other than motor- tomer requirements,” including variants like personnel transports
fornia, Florida, Illinois, New York, cycles, may not exceed a sound and command-and-control trucks. Both gas and diesel versions
and Texas were the top five level of 95 dB when tested would be offered to military customers. Pending interest in the mili-
states for outdoor recreation under a Society of Automotive tary marketplace, production could begin in the second half of 2020.
as a percentage of total federal Engineers (SAE) procedure. SB
GDP. In terms of percentage of 112 does not change this.
state GDP, outdoor recreation
STOCK LEXUS
TOPS REBELLE
RALLY
T he X Elles, Rachelle Croft
and Taylor Pawley, drove
a bone-stock Lexus GX 460 to
win the eight-day, 1,440-mile,
women’s off-road rally raid
known as the Rebelle Rally.
The Rebelle is different from
other navigational rallies,
not just because its partici-
pants are all female but also
because the teams must find FORD & ARB CO-DEVELOP PARTS
F
their way through the Califor- peting for eight days with 80 ord Performance and ARB 4x4 Accessories have announced
nia and Nevada desert terrain incredible women, you can’t they will design and develop off-road accessories and vehicle
by using old-school naviga- help but come out on the recovery equipment for Ford vehicles. The first result of the
tional tools like a map and a other side a different person. collaboration will be a winch-ready bumper for the Ford Ranger,
compass. No cellphones or This rally pushes you out of available in 2020 as a dealer-installed option for $1,495. The bum-
per will attach to existing mounting points, is compatible with the
GPS allowed. your comfort zone to show
Ranger’s safety systems and sensors, and will be covered by a Ford
“Our experience in this you what you are capable of Performance limited warranty. Ford says it can accommodate a
Rally will be one I never forget with a group of women cheer- number of Warn winches and Rigid LED light bars, and has antenna
and one of the hardest things ing and helping each other and sand-flag mounts.
I’ve done,” said Croft. “Com- along the entire way.”
TITAN XD ENHANCED FOR 2020 CALENDAR
L •
ike its lighter-duty stablemate, Nissan’s Titan
FEB. 1: Tire Repair Clinic
XD has been revised for 2020 with retooled
by Badlands Off-Road
sheetmetal, a retuned gas V-8 backed by a
Adventures, Hawthorne, CA.
new transmission, a redesigned interior, and new
Info: 310.613.5473,
driver-assist safety systems.
4x4training.com
To refresh your memory, the XD is a heavier-
duty version of the standard Titan. It rides on a
beefier version of the standard Titan’s platform
• FEB. 8: Getting Started Off-
Road Driving Clinic
with a fully boxed and reinforced ladder frame. The by Badlands Off-Road
wheelbase is about 15 inches longer so the XD can Adventures, Gorman, CA. Info:
accommodate a 61⁄2 -foot bed behind the Crew Cab 310.613.5473,
body (the only body style offered for XD in 2020). 4x4training.com
The XD’s previous Cummins diesel option is gone;
now the only powertrain is the 5.6L Endurance
• FEB. 9: Getting Started Off-
Road Driving Clinic
gas V-8, retuned to make 400 hp and 413 lb-ft of by Badlands Off-Road
torque and backed by a new nine-speed automatic Adventures, Mojave, CA.
transmission. Info: 310.613.5473,
Nissan has not yet released tow or payload 4x4training.com
capacities but did say the XD has a range of avail-
able hitches, including a gooseneck hitch built into • FEB. 14-16: California Four
Wheel Drive Association 2020
the frame, and towing aids that include an inte-
Convention, Clovis, CA. Info:
grated trailer brake controller, trailer sway control,
800.4x4.funn,
tow/haul mode with downhill speed control, and a
cal4wheel.com
trailer light check system that enables one person
to check the turn signals, brake lights, and running
lights from inside the cab.
• FEB. 20-23: Laughlin Des-
ert Classic off-road race by
Best in the Desert, Laughlin,
NV. Info: bitd.com
MIAMI GETS THREE O FIVE EDITION JEEPS • FEB. 22: Rock Crawling
F
Clinic by Badlands Off-Road
or those of you not from the Sunshine State, 305 is Miami’s area Adventures, Lucerne Val-
code. Three O Five is also now the name of special-edition Jeep ley, CA. Info: 310.613.5473,
Wranglers and Gladiators, which debuted at Miami’s International 4x4training.com
Auto Show. The limited-edition Jeeps (255 Wranglers and 50 Gladi-
ators will be made for a total of 305) are based on Sport S models • FEB. 22-23: Getting Started
Off-Road Driving Clinic
painted in what Jeep is calling “Miami colors” of Punk’n Orange by Badlands Off-Road
Metallic or Bright White. They are equipped to suit “Miami’s outdoor Adventures, Borrego Springs,
vibrant environment” with Sky One-touch powered tops, Sport LED CA. Info: 310.613.5473,
lighting, and Miami-themed graphics. The tube doors, winch bum- 4x4training.com
pers, and other accessories on the Jeeps in the photos are options
that can be installed at Jeep dealers.
• NOTE: Have an event? Send
date, location, a description
of the event, and contact
info (such as email, phone, or
website) to 4wheeloffroad@
enthusiastnetwork.com.
Please submit your info at
least four months before the
event due to our press lead
times.

FEATURE
GO WATCH
THE ULTIMATE
ADVENTURE 2019
VIDEOS
BY Christian Hazel
EDITOR@4WOR.COM
FREE ON MOTOR TREND’S
YOUTUBE CHANNEL!
PHOTOGRAPHY HARRY WAGNER
E
VERY YEAR OUR ULTIMATE
Adventure goes somewhere
new. Only once has the event
retraced its steps, hitting the
Rubicon Trail in 2001 and then
again in 2016. Otherwise, every
mile on- and off-road has been
new ground. But with 2019 being the 20th
anniversary of the event’s beginning, we
took things up a notch and began the
event in Alaska. With some participants
driving nearly 5,000 miles just to get to
the starting point in Wasilla, everything
about UA 2019 was big. Now you can see
for yourself because all five of our videos
from the weeklong adventure are live on
Motor Trend’s YouTube channel. Go visit
youtube.com/user/MotorTrend and enjoy
the entire UA2019 playlist. And if that’s
not enough for you, the previous years’
videos are on motortrendondemand.com.

ULTIMATE ADVENTURE 2019 SPONSORS
CUMMINS INC. FALKEN TIRE OFFROAD POWER PRODUCTS SMITTYBILT
Official Turbo Diesel Official Tire Official Retailer Official Winch
800.286.6467 800.723.2553 855.463.3762 888.717.5797
cumminsrepower.com falkentire.com offroadpowerproducts.com smittybilt.com
DANA IH PARTS AMERICA PREMIER POWER WELDER VOODOO OFFROAD

Official Crate Axle Official IH Truck & Scout Parts Official Onboard Welder Official Recovery Rope
800.621.8084 530.274.1795 800.541.1817 844.866.3661
crateaxle.com ihpartsamerica.com premierpowerwelder.com voodoooffroad.com
FAB FOURS OFFROAD DESIGN SKYJACKER SUSPENSIONS

Official Bumper Official Transfer Case Official Shock & Suspension
866.385.1905 970.945.7777 318.388.0816
fabfours.com offroaddesign.com skyjacker.com

FEATURE
E
OUR FAVORITE
VERY YEAR WE GO TO THE SPECIALTY EQUIPMENT MARKET
Association (SEMA) Show and wade through chromed-out show
PRODUCTS AMONG
trucks and over-the-top 4x4s to find the products that will actually
make your off-road vehicle more capable on the trail. As it was last
year, the Jeep Wrangler JL was a popular platform, but this year
THE OFFERINGS AT the Jeep Gladiator JT was definitely the darling of the show. We
skipped the halo headlights and 26-inch wheels in favor of things
THE SEMA SHOW like suspension components that increase articulation and tires that will
allow you to claw your way up the gnarliest of obstacles.
BY Harry Wagner EDITOR@4WOR.COM PHOTOGRAPHY HARRY WAGNER AND COURTESY OF SEMA
BEST OF SEMA

3
2 5 7
1
MICKEY THOMPSON INFORMATION: Switch-Pros by Off Road the features of the Ultimate Dana 60, like
BAJA PRO XS Engineering, 949.581.2991, switchpros.com 10-inch ring gears, massive Spicer SPL
We thought Mickey Thompson was nuts -70 U-joints, and 35-spline chromoly axle
last year when the tire maker released
3
ARB ZERO FRIDGE FREEZER shafts. INFORMATION: Dana Crate Axle,
the 43-inch Baja Pro X. Well, now we have ARB unveiled a new freezer-fridge with spicerparts.com
the Baja Pro XS, the world’s tallest DOT- dual climate zones, a reversable quick-
approved light truck tire. Designed after release lid, Bluetooth controls, and the 6
COME-UP BLAZER M3 WINCH
the extreme Baja Pro X, the Baja Pro XS is most efficient compressor on the market. We thought that Come-Up’s Blazer winch
street legal with a tough four-ply bias con- The Zero fridge will be available in 73- and with two motors was nuts, but now the
struction. They will be available in 10 sizes, 101-quart sizes. INFORMATION: ARB USA, company offers the Blazer M3 with three
ranging from 35 inches tall all the way up 866.293.9078, arbusa.com 8.0hp motors for a line speed up to 259
to a ridiculous 58. Mickey Thompson also fpm! Three different gear ratios are offered
introduced the Baja Boss tire in a sticky 4
ROTOPAX ROLLPAX depending on how much pulling power you
compound for dedicated rockcrawlers. The new RollpaX from RotopaX is a round need, and the free spool is pneumatically
INFORMATION: Mickey Thompson Perfor- fuel storage container that includes tube controlled. INFORMATION: Come-Up Winch,
mance Tires & Wheels, 800.222.9092, clamps to mount to rollcages and tire 503.783.6142, comeupusa.com
mickeythompsontires.com carriers. The Rollpax holds 11⁄2 gallons of
fuel and is available with CNC aluminum 7
SKYJACKER GLADIATOR LONG-
2
SWITCH PROS RCR-FORCE 12 clamps in a variety of sizes. INFORMATION: TRAVEL SUSPENSION SYSTEM
This patent-pending, 12-switch power RotopaX, rotopax.com Skyjacker unveiled its 41⁄2 -inch Dual Rate
system from Switch Pros uses solid state Long Travel coils for the Jeep Gladiator.
technology for a 150-amp capacity that 5
BRACKETLESS ULTIMATE These coils have a light spring rate at ride
controls 17 outputs. Programming options DANA 60 height and a second, higher rate that only
include dimming memory, multi-output Dana is offering Ultimate Dana 60 axles engages during coil compression. Long
switches, and On-On-Off. The switch panel without mounting brackets, allowing travel allows the coils to expand without
has active switch indicators with custom for installation in virtually any applica- unseating as the suspension terrain chang-
labels and an RCR-Touch bezel to assist tion, with the end-user adding the proper es. Accompanied by long-travel Skyjacker
in switch selection while you’re wearing mounting brackets. Other than the dele- shocks to match. INFORMATION: Skyjacker
gloves. Plus, we love that it is made in USA. tion of the brackets, the axles include all Suspensions, 318.388.0816, skyjacker.com
BEST OF SEMA
10
“ There are
already a host of
8
Gladiator parts
”
8
PRO EAGLE PHOENIX AIR JACK 10
ADVANCE ADAPTERS
Pro Eagle’s new lightweight, portable, ATLAS TRANSFER CASE
CO2-operated jack is made specifically to FOR JEEP JL AND JT
carry on UTVs and other lightweight vehi- This gear-driven Atlas from Advance
cles—but we anticipate a fullsize option Adapters is designed as a direct replace-
in the near future. Since it provides over 2 ment for the OEM transfer case in the
feet of lift height, it is perfect for both utility Jeep Wrangler JL and Gladiator JT. The
and sport UTVs. It utilizes 20- to 25-gram kit includes a new adapter to mate to
CO2 canisters that attach to an easy-to-use the 850RE automatic transmission
regulator, allowing the user to control lift and is designed to retain the original
height and lift speed. INFORMATION: Pro driveshafts, support mount, and shifter
Eagle, 310-513-8222, proeagle.com assembly while also offering a 2WD-Lo
option. INFORMATION: Advance Adapters,
9
PRO COMP FORD RANGER 800.350.2223, advanceadapters.com
BLACK SERIES 2.5-INCH
COILOVERS 11
YOKOHAMA GEOLANDAR X-AT
Pro Comp’s 2 ⁄2 -inch monotube shock
1
Rugged gets redefined with Yoko-
design features an impact-forged, hard- hama’s new Geolandar X-AT extreme
anodized aluminum body with strength and all-terrain tire. The X-AT is available in 27
cooling in mind. Other high-end features sizes, for wheels from 15 to 22 inches in
include an induction-hardened, chrome- diameter. It offers ultimate off-road per-
plated shaft and internal floating piston to formance without sacrificing any on-road
provide improved damping response and comfort, making it a great performance
eliminate cavitation. They are designed to upgrade for a variety of pickup trucks
maximize wheel travel on the Ford Ranger and SUVs, no matter how or where they’re
for fast off-road use. INFORMATION: Pro driven. INFORMATION: Yokohama Tire,
Comp, 310.900.5500, procompusa.com 800.423.4544, yokohamatire.com
4WHEELOFFROAD.COM
THE ONLY BRAKES
MADE THIS WAY
Kevlar® based low abrasion, low dust, Edge chamfers for reduced chatter
11 high performance compound in a choice and improved pad
12 of different blends for every driving style contact
and vehicle
NUCAP® NRS® hook

finished backing plates
for superb bond
Noise shims on piston strength and zero
Unique "Brake-In™" side of pad for totally chance of pad de-bond
coating conditions silent braking
rotors fast at pad
install and seats new
pads quicker
13
12
DYNOMAX JEEP GLADIATOR
QUIETCRAWLER PERFORMANCE
EXHAUST SYSTEM GD BSD
The DynoMax QuietCrawler exhaust sys-
tem was designed for maximum clearance
for on- and off-road driving and includes USR RK
two mufflers. An oval Super Turbo muffler
helps to reduce sound without sacrificing
performance, and a Race Bullet muffler
acts like a resonator and helps to eliminate
drone. INFORMATION: DynoMax Exhaust,
734.243.8000, dynomax.com
Combine your choice of these quality UK made EBC pads with our
13
FACTOR 55 ROPE sport rotors which arrive with “thermic black” corrosion resistant
RETENTION PULLEY
Factor 55 has developed the world’s first coated finish for great looking brakes that COST less and STOP faster.
winch friction pulley with a patented rope
retention feature. During momentary slack,
the innovative rubber fingers prevent syn-
thetic winch rope from escaping the pulley
groove, preventing premature rope failure.
Billet machined from 6000-series aluminum
and hard anodized to Mil-A-8625 F, the pul-
ley is, like all Factor 55 products, the new Buy ONLINE or from your favorite
pulley is made in the USA. INFORMATION:
Factor 55, 208.639.1674, factor55.com performance store or order at Autozone. www.ebcbrakes.com

BEST OF SEMA
14
17
15 19
16 18 20
14
PROCHARGER JEEP 16
SMITTYBILT GEN3 XRC WINCH open shoulders providing additional biting
GLADIATOR AND WRANGLER The all-new XRC Gen3 Winch by Smitty- edges for superior traction on all terrains.
SUPERCHARGER SYSTEM bilt includes a 7.0hp motor and boasts an Alternating step-down grooves integrated
The complete ProCharger Intercooled average line speed increase of 12 percent into the shoulder blocks provide tread rigid-
Supercharger System for the Jeep Gladia- over its Gen2 predecessor, adding more ity for enhanced stability on and off the road,
tor JT and Wrangler JL features the P-1SC-1 speed and power with less amperage draw while the tread pattern optimizes the pitch
supercharger and is 50-state legal. It adds at load. The magnetic remote controller sequence for a quieter ride. INFORMATION:
a 45 percent gain in horsepower, making has a Load Indicator Warning System with Milestar Tires, milestartires.com
425 hp from a stock 3.6L V-6 Jeep. This a built-in flashlight. INFORMATION: Smitty-
bolt-on design is available in satin, pol- bilt, 888.717.5797, smittybilt.com RSI SMARTCAP
19
ished, or black finish options. ProCharger SMARTKITCHEN

also has new systems for Toyota 4.0L V-6 17
RUGGED RIDGE ROOF RACK Part of a system of accessories that
engines used in Tacomas and 4Runners. FOR JLU HARDTOP maximize the space in your bed to fit your
INFORMATION: ProCharger Supercharger The new Rugged Ridge roof rack for lifestyle, RSI SmartCap’s SmartKitchen
Systems, 913.338.2886, procharger.com Wrangler JLs uses a low-profile design installs into the SmartCap’s Gullwing door in
and sturdy steel construction so you can under 15 minutes—in when you need it, out
15
ENERGY SUSPENSION carry an extra 150 pounds of cargo over- when you don’t. The turnkey camp kitchen
PROGRESSIVE TOYOTA head with a minimal height increase, mak- is comprised of a stove, a cutting board,
BUMPSTOPS ing it perfect for overlanding and the avid and secure storage for the included dishes,
Designed by Energy Suspension’s outdoorsmen. A rack-mounted basket cookware, and spices. INFORMATION: RSI
innovative engineers, these rear coil isola- helps anchor your cargo, while skeleton- SmartCap, 775.636.9664, rsismartcap.com
tors and bumpstops feature progressive style roof rails make securing the load
durometers to prevent hard and uncom- with bungee cords or ratchet straps a 20
UNIVERSAL CUMMINS
fortable compression. A direct-fit replace- breeze. INFORMATION: Rugged Ridge, TO ALLISON ADAPTER
ment and massive upgrade over the rigid 770.614.6101, ruggedridge.com Custom Automatic Conversions has
rubber OE bumpstop, they are available for designed a universal engine adapter and flex-
2003-2019 Toyota 4Runners, 2007-2014 FJ 18
MILESTAR PATAGONIA X/T plate for all years of Cummins engines from
Cruisers, and 2003-2019 Lexus GX470/460. The Patagonia X/T features a cut- and chip- 4B to 6B, 24-Valve 5.9L Common Rail, and
INFORMATION: Energy Suspension, resistant compound with a rugged three- 6.7L Common Rail engines to mate to a GM
949.361.3935, energysuspension.com ply sidewall that is utilized for enhanced Allison 1000 bellhousing. INFORMATION: Cus-
durability in rough conditions. Alternating tom Automatic Conversions, 865.253.1133
COVER SECTION: E-Z DRIVEWAY INSTALLS
BY Jay Kopycinski while buzzards circled overhead. Fast- the transmission internals, fluid lines, and
forward into the modern world where auto- cooler(s). We’ll show you a fairly easy way
EDITOR@4WOR.COM
PHOTOGRAPHY JAY KOPYCINSKI matic transmissions are now very reliable to do a fluid replacement in your driveway
T
and commonly in use by four-wheelers. without much hassle.
HERE WAS A TIME WHEN REAL Hydraulic fluid is the lifeblood of an The basic idea is to use the transmis-
wheelers supposedly only drove automatic transmission, and heat and con- sion’s own internal pump to push fluid out
stick. Automatic transmissions tamination are the enemies of that precious of a disconnected line, and replace with
were some mysterious slush- liquid. In general, transmission fluid starts new fluid going into the pan. No solvents
box positioned between your to degrade as temperature rises, and that or other chemicals are introduced into the
engine and transfer case. Hit a degradation is said to be cumulative over the system, and no abnormal pressures are
rock with the transmission pan life of the fluid. In other words, the fluid deg- applied like they can be in other methods
and all the magic fluid would leave said radation can occur during short exposure to of flushing. Note that some transmissions
transmission, rendering your rig useless high heat or during longer exposure to mod- will run the pump in any shifter position,
FRESH
erately high heat. Hence, it’s a good idea but others may not pump while the trans-
to change the fluid at recommended mission is in the park condition.
regular or severe-service intervals. We finished the work in just a couple
Most automatic transmissions hold of hours with common tools and a few
roughly 10-14 quarts of fluid. If you supplies that we used to drain and catch
simply drain what’s in the pan, you will the old fluid. While we were at it, we also
FLUID
typically only get about a third of the dropped the pan and installed a fresh
fluid out of the transmission. The torque filter, so our transmission should be all set
converter holds a good amount, as do for the next few years of driving.
DIY AUTO
TRANS
FLUSH
& FILL

1 We gathered enough fluid to satisfy the
capacity of our Jeep transmission plus some,
along with a new filter, a 5-gallon bucket, and
some vinyl tubing. Automatic transmission fluid
(ATF) can be specific to the manufacturer. In
our case, this 2006 Jeep Wrangler uses ATF+4
synthetic fluid.
2 We started by accessing a drain point where

the transmission line leaves the radiator
cooler, sending fluid back towards the input of
the transmission. Our stock cooler uses a snap-
in style fitting. You simply use a hook tool to pull
off the retainer clip, and the hose line pulls free
from the fitting. If you have an auxiliary cooler
downstream from your radiator cooler, it might
be best to drain from the output of that cooler.
3 We used a barbed fitting (Hayden Automo-

tive 397) and a length of 3⁄8 -inch PVC clear
vinyl tubing run into the plastic bucket to catch
the old fluid.
1
4 We plugged our makeshift drain line into
the outlet fitting at the radiator cooler. You
may also find that some fluid will drain from the
disconnected line.
5 We started the warmed-up Jeep and let the

engine run until about 3 quarts of old fluid
was expelled, then shut off the engine. This
action will rid the pan of a good bit of its fluid and
make it easier to remove the pan without making
a big mess. Be careful not to run longer as the
pump may start to draw air into the system.
6 Next, we unbolted and dropped the transmis-

sion pan. Since this pan has no drain plug, it
still held some fluid inside.
2 3
5 6
FRESH FLUID
7 9
7
“ If you simply drain what’s in the pan,
Here’s the transmission filter on the bottom of
the valve body. This one was held in place with
two small bolts. It was removed and discarded.
you will typically only get about a
8
”
A magnet inside the transmission pan
catches any steel particles that may pass
by. Ours had a small accumulation but nothing
third of the fluid out
alarming. Our old fluid was fairly dirty, and we
could tell from the slight sheen in the fluid that
the more than 100,000 vehicle miles had put a
bit of wear on the transmission internals.
9 We thoroughly cleaned the stamped steel

pan, then inspected the mating surface for
flatness. Running a flat, metal file across the
bolt holes helps ensure that there are no burrs
that could affect the pan seal.
10 An O-ring seals the filter outlet to the valve

body. Ensure that the old one is replaced
by a new, lubed one when the new filter is seated.
10 11
11 To reseal the transmission pan we used

a Lube Locker gasket. RTV silicone is
another option, but the Lube Locker is quick
and less messy, as the gasket comes with seal-
ing material already applied. The pan bolts
were torqued to OEM spec using the tightening
pattern provided with the gasket.
12 At this point, we added 4 quarts of

ATF through the transmission dipstick
tube. We repeated the pump out and replace
procedure (3 quarts at a time) several more
times until we had purged and replaced about
a dozen quarts of fluid. Then it was a matter of
warming up the engine and transmission, and
doing a final fluid level check. If you do get air
into the fluid and it foams, let it sit a while and
recover so you can run the transmission and
get an accurate measure of the fluid level.
SOURCE
LUBE LOCKER
775.246.6110
lubelocker.com
BY Trenton McGee Bumpers are usually the first things that us CJ-7 we were shoving it into places it
come to mind when people start talking really had no business being. We knew it
EDITOR@4WOR.COM
PHOTOGRAPHY TRENTON MCGEE about body armor, but other parts of your wasn’t going to be long before the nice
S
vehicle are just as vulnerable to damage. straight sheetmetal wasn’t so straight
HEETMETAL BUMPS AND The rear corners of vehicles seem to attract anymore. A few months after we pur-
bruises are an off-road fact damaging obstacles with regularity, par- chased the Jeep we spent a weekend
of life. Sooner or later you’re ticularly the passenger rear corner. But it’s adding armor to the body in an effort to
going to drop off a ledge just the rocker panels that are really the most keep the rocks at bay. The rear corners
right, rub up against that susceptible, and the longer the wheelbase, and rockers required drilling a few holes
rock you didn’t see, or hit the more likely that damage will happen. in the body, but it was a small price to pay
that stump you were trying Extra protection in these crucial areas can knowing we could attack more obstacles
to avoid. Minor scratches and dented mean the difference between a 4x4 that without fear of bending painted surfaces.
sheetmetal can be written off as charac- looks good for a long time and one that Installation required some attentions to
ter. Most of us don’t mind the hard-earned shows the scars of use and abuse. detail, but it’s really not that difficult to
bruises, but we’d just as soon keep them Shortly after we acquired our new-to- add some easy body armor upgrades.
to a minimum and add as much protection
as we can to keep the body of our 4x4s
reasonably straight.
ADD QUICK & EASY BODY

PROTECTION TO A CJ-7
ARMOR UP!
1
2 5
3 4
1 We call this 1984 Jeep CJ-7 our “weenie

wheeler,” as we’ve purposely avoided making
any major modifications to it or installing anything
disconnecting it from the hoses on the tank.
If your filler neck hoses are anything like ours,
they will likely disintegrate when they are dis-
larger than 33-inch tires. We’ve used this Jeep for turbed. Do yourself a favor and order new filler
everything from long-distance overland trips to neck hoses so you’ll have them on hand during
prerunning Ultimate Adventures to serving as a the corner installation.
dinghy for our motorhome. The rear corners and
rock sliders have saved the sheetmetal more times
than we can count, especially once we ruined our
weenie wheeler by adding lockers front and rear.
5 We test-fitted the rear corners and used
some welding clamps to hold them in place.
Even though we didn’t have to, we removed
the rear fender flares to make fine-tuning the
2 We purchased the Warrior rear corners

from an online retailer. They are available in
several different varieties, including aluminum
placement of the rear corners easier. You want
to make sure that the top edge follows the body
line as that’s the most visible portion of the
diamond plate, and we opted for the smooth corner. Overall we were impressed with how the
steel corners that are powdercoated black corners fit, especially considering the 35-year-
because we’re allergic to anything shiny. In old sheetmetal and the worn-out dies that
addition to finish, the corners can be ordered stamped them out in 1984.
with or without the taillight holes, gas filler neck
hole, and so on. The corners are constructed
of 1⁄8 -inch-thick steel. This seems thin at first
glance, but remember, these are designed to
6 As well as they fit, we still had to make some
adjustments and small compromises to get
the best overall body alignment, We prioritized
reinforce the corner and spread the force of any lining up the top edge and the side edge closest
6
impacts across a larger area. They won’t resist to the tailgate, as these would be the most vis-
a major impact, but they’re more than adequate ible. The taillight holes on both sides lined up per-
for average trail bumps and scrapes. fectly. There were no holes for the spare tire car-
rier, so we marked those from the inside as well as
3 Of course, everything needs to be removed

from the rear corners in order to install the
the corner mounting holes with a silver sharpie.
corner armor. In our case, that included the

taillights, license plate holder, spare tire car-
rier, soft-top snaps, and any emblems. The CJ-7
7 The corners included black rivets to attach
them to the sheetmetal. That is probably ade-
quate for a street Jeep, but we intend to actually
emblem came right off with a little heat from a use these corners and wanted something a little
heat gun to loosen the adhesive. Our current stronger. We opted to pick up some No. 10 stain-
soft top is snapless, so it’s a nice bonus that the less steel button-head screws and nyloc nuts to
corners cover up the old snap holes. secure the corners to the body instead. This is
not only stronger, but it also makes the corners
4 On the passenger side, the filler neck needs

to be temporarily removed, which involves
easily removable if we ever get around to paint-
ing the Jeep something other than turd-brown. 7
ARMOR UP!
8 We purposely drilled the spare tire car-

rier mounting holes a little big so that the
built-in adjustment could be retained. Another
the body. The sliders will work with factory
or aftermarket flares, and they wrap around
underneath the pinch weld of the rocker to
unexpected benefit of the rear corners is that offer additional protection. Like the corners,
they help reinforce the tire carrier attachment these are intended to spread any impacts
points on the body, which are known to crack across a broad section of sheetmetal, there-
when you put larger tires on the carrier. fore resisting body damage.
9 The procedure for the passenger side was

largely the same as the driver, just with
extra holes for the tire carrier mounts. You can
12 We used the sliders as a template to
mark and drill the mounting holes. We
installed them using the supplied 1⁄4 -inch
see how well both the taillight and gas filler stainless hardware. Though we would have
neck holes lined up with the body, making it like to have seen bigger hardware, there were
very easy to bolt everything back together. several places where 5⁄16 - or 3⁄8 -inch hardware
8
would not have grabbed a sufficient amount
10 Not many people are making new prod-

ucts for old Jeeps these days, but Rusty’s
Off-Road recently released its own version of
of sheetmetal. We have since “tested” the
strength of the sliders several times, including
putting the full weight of the Jeep on one of
rock sliders for the CJ-7. These beefy sliders them. They performed perfectly. We appreci-
are constructed of 3⁄16 -inch steel throughout ate the fit and finish, such as where the slider
and are designed to bolt to the body. They also aligns perfectly with the body line present in
incorporate a step constructed of 1.50x0.120- the front fenders.
wall DOM tubing and 1⁄8 -inch dimple-dyed
plate. Not just a handy step, this addition also
helps keep rocks and trees away from the side SOURCES
and the windshield frame.
RUSTY’S OFF-ROAD WARRIOR
PRODUCTS PRODUCTS
9 11 We used a floor jack to hold the rock

sliders in place and line them up with
256.442.0607
rustysoffroad.com
888.220.6861
warriorproducts.com
10
11 12
BY Verne Simons things may be worn out or broken. Our
1998 Dodge Ram 2500 4x4 Quad Cab with
VERNE.SIMONS@4WOR.COM
PHOTOGRAPHY VERNE SIMONS the 12-valve Cummins diesel is the perfect
O
example of the kind of old truck we like.
LD TRUCKS MAKE OUR HEARTS Sure, we occasionally find ourselves look-
go pitter-patter, our cheeks ing at newer trucks and thinking, Hey, that
flush pink, and our eyes go all might be nice! But at the end of the day
googly. We’re smitten. Sure, old the old Dodge is still parked in the drive-
trucks generally have many way. It’s too useful not to keep around for
miles and a few dings and towing, scrap metal runs, parts runs, and
dents and some rust, but that’s more. Plus, despite temptation, we can’t
just fine with us. We aren’t perfect either. justify replacing it just yet.
Also, old trucks have stood the test of time. The truck does have issues associated
Their mechanics, electronics, and more are with its 21 years (man, it’s old enough to
generally simpler, more consistent, and drink). So what should we do? Well, how
easier to work on. Some might say reliable. about we spend some time and money fix-
And even if they do have issues, their issues ing the old girl up? We’ve done this before,
are generally known. Furthermore, as fans and we will do it again. This time we focus
of saving the world for future generations, on fixing up the dash a little bit in hopes
we know that reuse is better than recycling that we can make the old Dodge feel a
(OK, we’re also consummate cheapskates bit newer and make it last a little longer.
and would just as soon not make payments We will do this with a little elbow grease,
on a new truck right now). some glues, adhesives, steel, and a little
Still old trucks are, well, old. That means help from RockAuto.com. 1
DASH REHASH FIXING AN AGED TRUCK DASH

3 5
4 6
1 We’re pretty sure our old Dodge has spent

most of its life outside. It is a basic truck,
nothing fancy. We’re also pretty sure it has
then the cubby pivoted up and was attached via
tabs and screws above. The plastic of the lower
part acted like a hinge—a plastic hinge. No sur-
spent most of its life west of the Mississippi and prise that after 19 or 20 years the plastic hinge
has, at least for the past several years, spent finally gave up the ghost, but not until after the
time outside in the deserts of the Southwest. upper mounts tabs broke off the back of the
Heat, time, and UV rays have made the plastic cubby. We were left with a large, unsightly hole
dash brittle and cracked it in a few places. The in our dash and a loose former cubby floating
2 truck’s dash also has a molded-in cubbyhole around the inside of the truck. These little steel
that flexed, cracked, and left its moorings a few hinges are riveted to the two lower bits of plastic
years back. Our plan is to spend a few hours and so the cubby can be secured and then pivot up
a little cash to clean this all up. into place, replacing the plastic hinge.
2 This is our pièce de résistance of the dash

rehash. It’s a dash cover from RockAuto.
com. Our Dodge dash overlay costs $229.79 (PN
5 Here are the upper two mounts for the cubby.
These two tabs broke off shortly after we
got the truck; maybe one was already broken.
22802LL) and comes in a choice of 12 colors. Then the cubby flopped down and finished off
We tried to pick what was closest to our origi- the aforementioned plastic hinge. Since the
nal dash. Installation is simple. First, clean off plastic is brittle, we’re pretty sure using only JB
the old dash with a window cleaner containing Weld to hold the bits together would just move
ammonia. Then make sure that any cracks are the crack. So we glued the tabs back in place
about level (one side not higher than the other). using the epoxy and then used Automotive Goop
Test-fit the dash cover. Add the included silicone to attach some steel backing. The Automotive
glue sparingly, following the instructions (these Goop is supposed to remain flexible yet strong
parts will flex, expand, and retract differently despite heat, vibrations, and so on. Hopefully
due to heat). Finally, pop the part into place. this will last another 21 years.
3 Then you have to make sure the dash cover is

held in contact with the dash. We used bits
of cardboard folded and tucked strategically
6 Here’s the cubby back in its place as God
and the Dodge Brothers intended. Sure, you
can see the rivets and it doesn’t fit quite as well
and also used some “weights” we had around as it did from the factory, but it sure is better
the shop. The rags help protect the dash cover than it was before. Respect your elders, you
from the weights. We waited overnight, after darn whippersnappers!
which the unit was well attached.
SOURCE
4 This is the back and bottom of our Dodges
factory dash cubby. One bit of plastic was
screwed to the bottom of the dash structure, and
ROCKAUTO
rockauto.com
TECHNICAL
THE COST
OF FREE
The problem is money, the root of all evil. We apparently would
prefer to spend it on many ragged pieces of 4x4 crap than one or
two nicer 4x4 pieces of crap. We hoard derelict off-road vehicles
and projects in hopes that we can one day take them on an adven-
ture off the beaten (more like “off the paved”) path. That’s why
free or nearly free trucks and 4x4s are very hard for us to refuse.
This is the exact problem with the 1997 Crew Cab Chevy
TRYING TO REVIVE A 3500HD truck that is the focus of this article. It seemed free, a
deal too good to pass up.
CHEVY VORTEC 454

Of course, working at the world’s largest off-road magazine
only enables our habit, justifying some, if not all, of our projects
because we need them for work. (Yeah, that’s it!) We introduced
this truck to you before, and we even started collecting parts
BYVerne Simons VERNE.SIMONS@4WOR.COM
for the build, namely the locked and loaded 21⁄2 -ton axles we
PHOTOGRAPHY VERNE SIMONS
B
plan to tuck under it. It’s a free truck, which is one of the most
AD IDEAS? WE’VE HAD THEM, AND PROBABLY WILL sought-after trucks for people with our particular addiction. And
continue to have them despite our best efforts. while it’s not four-wheel drive (yet), it does have a 454 engine, a
Like a junkie, we always seem to be looking for that beefy transmission, and solid front and rear axles. That’s right—
next fix, only our heroin comes in the form of trucks leaf-sprung beam front axle. These issues, we’ve convinced our-
and 4x4. We’re not junkies—we’re junkys. We crave selves, are easy to overcome given our current path of enabling
capable off-road rigs both big and small. And like our addiction, even if it means spending money on a free truck.
most addictions, it creates a problem. But at what cost…really?
1 Here’s evidence that this Chevy 3500HD
hasn’t moved in many years. It was last
registered in 2002. That means there is a good
a sputter of life. So that’s good news. The engine
cranks and we have spark.
and fuel pressure at the port at the intake mani-
fold. Nada, no fuel. Our next step was to check
the fuel pump relay, which we could feel clicking
chance it has been parked since then, but why?
It’s a 1997, so it was only 5 years old when it was
parked and only has 112,000 miles on it. This
3 We have spark, but oddly, several of the
spark plug wires had been pulled off the
engine, and some were damaged. We were
with the cycle of the key, so the pump should be
running. From there we needed to establish why
the pump wasn’t running. We located the fac-
truck, along with two others like it, were sold not sure what to make of that. We’d probably tory plug that sends wires to and from the fuel
to our buddy as assets when a company that replace the plugs and wires on an engine like pump/tank and checked for voltage, which was
owned them went bankrupt. This buddy, Mike, this that has been sitting idle for this long present with cycling the key. Next, we dropped
basically told us that if we can get the truck anyways, so meh! Duralast Wireset (PN 4639, the tank and pulled the pump and found that the
running we can do with it what we want. We’re $38.99) fits the bill and the truck. pump and primary filter (fuel sock) were abso-
thinking big tires and Rockwell 21⁄2 -ton axles! lutely gummed up with about half a pound of
2 With a truck that’s been parked as long as

this one has been, you’ve got to start with
4 We also tossed in a Duralast Gold Ignition
Cap and Rotor Kit (PN DR2031G, $56.99) for
good measure—and that was a good call. The
some tarlike substance. Maybe the remainder of
15-year-old gasoline?
the basics. First, we had to see if the engine

would turn over. From there, most engines
want to run, but need fuel, air, and spark. First
cap on the truck looked OK, but the rotor wasn’t
properly tightened in the distributor. As a result,
the holes had wallowed out. We’re guessing that
6 Freelancer Trent McGee is a great friend to
have, and for reasons only he will ever know
he’s the one who ended up cleaning most of
step was to hook up a battery and turn the key didn’t help performance on the old Vortec 454. the remaining “tar” out of the Chevy’s fuel tank
on the old truck. We popped a Duralast Plati- using fresh gas and rags. (Thanks, Trent! Sorry,
num Battery AGM Group Size 78 with 740 CCA
($194.99 with an $18 core) into the battery
tray and hooked up the terminals. The engine
5 Since the engine didn’t run on its own, the
next step was to make sure it was getting
fuel, and to make sure the fuel is getting to the
Trent! Now that it has been several weeks, does
your hand still smell like old gas?) Poor bastard.
A good friend is worth his weight in gold.
turned over, and a spray of starter fluid gave us engine. With the key turned, we checked for fuel
1 4 5
“ Free
trucks
are very
hard to
2 refuse
”
3 6
THE COST OF FREE
7 9
8 10
7 With the tank dropped, we installed a Delphi

Gasoline Fuel Pump (PN CFE0114, $72.99)
from our local AutoZone store. And with the
injectors in place, we were feeling pretty con-
fident that the truck would fire right up. But
we were wrong. The truck cranked away but
new pump installed, about 3 gallons of fresh wouldn’t catch and run. At this point our story
gas, and the tank roughly back in place, we goes from hopefully optimistic to frowny face.
cycled the key. Now we were reading just over
60 psi at the fuel rail, which is just where we
want the fuel pressure…but still, we lacked fire. 11 From here we decided to hedge our bets.
That started with verifying that the dis-
tributor was installed correctly, so we mechani-
8 We surmised that the fuel injectors were

probably not firing, so the fuel, although
at the rail, was not getting into the intake and
cally rotated the engine until the timing marks
for TDC on the harmonic balancer lined up and
checked the distributor. It was wrong. Another
thus not entering the combustion chamber. This 180 degrees of rotation still yielded, at best,
could be because of a lack of signal, or because a timing conflict. So we pulled the driver-side
the solenoids in the injectors were gummed up valve cover in order to verify that the engine
from old fuel. The first step is to test for a fire was at TDC. What we instead verified was that
signal at the injector, and the easiest way to do the engine wasn’t going to run easily without
that is with a set of noid lights, but that meant more work. A pushrod was bent and an exhaust
removing the upper intake manifold. Our noid valve was stuck open—and that valve has
light test confirmed that the injector was get- almost certainly come in contact with that No. 1
ting a “fire” signal, so the next step is to pull piston while we fruitlessly spun the engine try-
and replace, or clean, the injectors. ing to get it to run. As they say, nothing is free.
The good news is our buddy Mike has a nearly
9 We found a local shop, Rods Carburetor in

Phoenix, to clean and flow-test our injec-
tors. At $120 for all eight, the service was a
identical truck with a nearly identical Vortec
454. And while we haven’t made a solid decision
on what course to take next, maybe we’ll try to
steal since most injectors that will work for this start a different free truck that’s also been sit-
vehicle range from about $120 to $60 each. We ting for 15 years. What have we got to lose?
reinstalled them in the fuel rail and put the upper
intake back together to see if the rig would run.
SOURCES
10 We got everything buttoned back up,
including a new Duralast Serpentine Belt
1005K6 ($25.99). With the freshly cleansed
AUTOZONE
866.853.6459
autozone.com
DURALAST PARTS
800.288.696
duralastparts.com 11
HOSTED BY: Fred Williams and Dave Chappelle
Stream all-new episodes now, only on
Go to: MotorTrend.com/4wmag
BY Verne Simons lowest point of your 4x4, but along with the aren’t necessarily quick and easy.
positives comes the fact that larger tires Some JK Wrangler owners are more
PHOTOGRAPHY VERNE SIMONS (and wheels) reduce both the acceleration than willing to get fancy with lots of after-
and braking of just about any 4x4. Bummer. market brake modifications, but Dynatrac
T’S A FACT. ADDING LARGER TIRES Luckily there are solutions. We’ve has an easy bold-on brake upgrade that
to any off-road 4x4 is one of the talked many times about regearing axles doesn’t even require bleeding the brakes.
first things people do. And with to regain some of the acceleration, econ- And despite our lack of scientific acumen,
the extraordinary popularity of omy, and feel when larger tires are added. our simple tests showed that this simple
the JK Wrangler as a daily driven That is a great, albeit expensive and solution dropped stopping times from
off-road platform, there are tens intense, solution. We’ve also talked about 60 mph by nearly 15 percent compared
of thousands of lifted JK Wran- improving the brake system to make to factory brakes. The Dynatrac ProGrip
glers running around in need of better your brakes slow down your big-tired Brake system is available for all 2007-
braking performance. 4x4 better. There are several ways that 2018 Jeep JK Wranglers and includes
The idea is simple: Larger tires equate the average dirthead can do that, but as new larger-than-factory brake rotors,
to more ground clearance underneath the with regearing, most brake modifications new brake caliper mounting brackets,
and new proprietary brake pads to give
your Wrangler’s factory front and rear
brakes a huge improvement in both mate-
rial and mechanical advantage.
EASY JEEP JK BIGGER

BRAKES
WRANGLER FOR YOUR

BIGGER JEEP
36
BRAKE UPGRADE
MARCH 2020 4-WHEEL & OFF-ROAD 4WHEELOFFROAD.COM
“ Larger tires
reduce both
acceleration and
1
braking of any 4x4
The Dynatrac ProGrip Brake System for Jeep
JK Wranglers comes with larger rotors, new
”
larger (and beefier) brake caliper mounts, and
new proprietary brake pads for both front and
rear. The Dynatrac rear rotors are 141⁄4 inches;
stock are 121⁄2 . The fronts are 131⁄2 inches;
stock are 12. The brake caliper mounts are
taller, allowing the factory calipers to clear the
larger disc diameter.
1 2 The kit comes with detailed instructions, and

the same basic steps apply to installation
of the new parts for both the front and the rear.
The front brake pads do come with anti-rattle
pads that need to be trimmed to fit where the
pads interface with the piston and caliper. We
also noticed that the front pads have a break-in
coating to help the new pads bed to the new
rotors. The instructions suggest using some
thread-locking compound on the hardware that
holds the calipers to the slide pins, and the cali-
per brackets to the axle or knuckle. We’ve seen
the larger bolts vibrate loose and fall out on the
trail, causing lots of problems.
3 The Dynatrac instructions clearly explain

all the hand tools you’ll need to get the job
done. Box end wrenches, 15mm and 13mm, are
used to reattach the caliper to the slide bolts.
2 3 You will also need an 18mm (we used a box
end wrench), 21mm (we used a socket and a
breaker bar), a brake caliper compressing tool
(or C-clamp), and the necessary hardware to
remove the wheels and tires from the Jeep.
4 The Dynatrac ProGrip Brake System fir JK

Wranglers is compatible with most after-
market 17-inch wheels, but wheel spacers are
required when using factory 17-inch wheels. We
were already running the best spacers available
from Spidertrax Offroad just to help keep the
larger tires out of the fenders and control arms
on our relatively low JKU. Both the Dynatrac
installation instructions and the company’s
website have a brake profile template that you
can trim to check clearance with your wheels.
With the brakes all buttoned up, we drove the
Jeep and snuck in some nonscientific, timed
60-0 mph braking tests to compare with the
baseline times of factory brakes. After four runs
the results were in, with a 14.4 percent improve-
ment in 60-0 stopping times. This should only
improve because we didn’t even give the new
brake pads time to seat in on the new rotors.
Pedal feel was also noticeably improved with
the new brakes.
SOURCES
DYNATRAC
714.421.4314
dynatrac.com
SPIDERTRAX
800.286.0898
4 spidertrax.com/products/wheel-spacer
FEATURE
1 Kaitlyn Tydeman’s 30th birthday was the motivation for the trip,
although the Sketchy Oregon Boys don’t need too much of an
excuse to go wheeling together. Here she is being spotted by her
2 The trail was tight and technical, with no bypasses around
most of the obstacles. That meant single file was
the plan for much of the day. We felt sorry for the
husband Graeme. While this is the stuff of nightmares for many cou- person who had to follow Dustin Emick in his
ples, these two have won rockcrawling competition and have the buggy with 42-inch BFGoodrich Krawlers,
trust and communication necessary for sketchy climbs like this one. portal axles, and rear steer.
BY Harry Wagner
EDITOR@4WOR.COM
NO BUGGY
SAID IT
WAS EASY
WHERE SHEETMETAL GOES TO DIE
W
HEN OUR FRIENDS FROM OREGON MADE The group ended up talking to rockcrawling competi-
a trip to Lake Tahoe recently, they asked tor and buggy builder Jesse Haines about where to wheel
for some recommendations on trails to near Reno. Haines built our lightweight Tracker, which
wheel. They had been to the Rubicon and we have wheeled all over the Hammers and every trail in
Fordyce, but were looking for more chal- Moab. “You don’t want to take the Tracker,” Haines told
lenging options. These guys all have tube us matter-of-factly. While our egos were bruised, we just
buggies and wear helmets when they go brought our camera instead of our rig. This was the right
rockcrawling, to give you an idea of what they consider fun. decision, as the trail left nearly everyone on their roof at
We have wheeled with the Sketchy Oregon Boys before, and least once. There are plenty of trails that you don’t need a
every trip we seem to end up with broken parts. buggy for, but this isn’t one of them.
1 2
NO BUGGY SAID IT WAS EASY
3 4
3 Randy Slawson debuted his new “bash

buggy” on this trip. The past King of the
Hammers winner focused on making his rec-
reational wheeler as light as possible with a
single 2-inch coilover at each corner and a
turbocharged Ecotec LTG engine under the 5
hood. These engines are found in Cadillacs and
use electric steering, so Slawson had to get
creative when adding a steering pump.
4 This trail gets your attention right off the

bat with a huge waterfall. While it is possible
to winch to the top, the trail only gets more dif-
ficult from here so if you need to winch on the
first obstacle you might want to find a new trail.
Chris Bradford was our ride for the day until he
broke a stub shaft in his GFab Jeep buggy.
6 7
5 Chris Basse brought his whole family out on
the trail, although his wife Leah and their
sons walked during the more challenging parts
of the trail. Ironically, Basse didn’t roll at all until
his family was all belted up and they were in the
gully at the bottom of the trail on the way out!
6 There isn’t much Samurai left on Robbie

Cox’s rig. The factory axles and suspension
are long gone, instead replaced with 1-ton
axles and coilover shocks.
7 Kaitlyn Tydeman’s Samurai buggy has

9-inch axles with Dana 60 knuckles. A turbo
1.6L is lightweight yet makes enough power to
spin the sticky 39-inch BFGoodrich Krawlers on
Trail-Gear Creeper wheels. Small-displacement
engines with forced induction seem to be very
popular with this crowd.
8 Mark Schultz taught us a trick about keep-

ing Maxxis Trepadors from burping air or
losing the inner bead, even with beadlocks.
These tires stick like glue, but the thick side-
walls mean that sometimes they want to come
off the rim at low pressure rather than conform
to the terrain. Schultz puts five wraps of duct
tape on the inside of each wheel next to the
inner bead to keep them from coming off. 8
9 When we wheeled with Will Bradford two
years ago his buggy had Toyota axles and
36-inch tires. Then last year he had 42-inch tires
on the poor Toyota axles. This year he added
a Dana 60 front axle and sticky 39-inch BFGo-
odrich Krawlers. Will is really happy with the
latest upgrades, his buggy went everywhere he
pointed it on this trip.
10 Dustin Emick bought this buggy from Port-

land’s James Treacy, so he automatically
gets a pass to go wheeling with the Sketchy Ore-
9 10 gon Boys. The buggy has rear steer, portal axles,
and 42-inch BFGoodrich Krawlers so it will go
just about anywhere. In the winter, Emick swaps
the tires out for 46-inch Mickey Thompson Baja
Claws and goes snow wheeling.
11 Robbie Cox’s Samurai buggy is shorter and

taller than most of the other vehicles that
were on the trail on this given day. That increased
the pucker factor on the steep climbs, but it also
allowed him to tiptoe through boulders like this
without getting hung up like others did.
11
12 The trail was a combination of big rocky
slabs and loose boulders that moved
around and made the line different for every
vehicle. When you look at how small Kaitlyn
Tydeman’s Samurai buggy is relative to this dry
waterfall, it really puts things into perspective.
13 There were two lines up this waterfall,

with the left life being more difficult than
the right line, with a severe off-camber section.
While the right line was easier, it required you
to drag the tube work along the ledge. You defi-
nitely don’t want sheetmetal on this trail.
14 Going up can be nerve-racking, but we

always find it more frightening to drop
down technical obstacles since you’re work-
ing against gravity. Nearly everyone on the trip
rolled at least once when descending the trail.
The most common cause was a tire dropping in a
hole and pitching the vehicle over.
12 13
“ A man’s got to know

14
4WHEELOFFROAD.COM
his limitations
4-WHEEL & OFF-ROAD MARCH 2020
” 41
BY Verne Simons camper, or other toy with your Jeep and
transmission temperature can become a
PHOTOGRAPHY VERNE SIMONS real problem. And that’s all without tak-
H
ing the additional heat larger and heavier
EAT IS THE ENEMY OF ANY wheels and tires put into the system due
and all automatic transmis- to the additional effort it takes for the
sion. We’ve been told that drivetrain to keep them spinning.
anything over 230 degrees Luckily we have a quick and easy solu-
will spell the rapid demise tion for anyone who puts heat into the
of any automatic transmis- transmission of their automatically shift-
sion, and the fact of the ed 2007-2018 Jeep Wrangler JK. Thanks
matter is it’s easy to heat slushboxes up. to the thermodynamics experts at Flex-A-
For one they are, with respect to cooling, Lite we can rest a bit easier knowing our
downwind of the engine making shedding JKU’s transmission has a bit more fluid,
heat to the ambient air that surrounds and a whole lot more cooling surface area.
them more difficult. Add in some hot laps Best part is the brand new Direct Fit Trans-
through the dunes, a slow crawl through mission Cooler (PN 31970) should have a
a technical rock trail in the desert, time street cost under $230 and is incredibly
stuck in traffic, or towing a small boat, quick and easy to install.
JEEP JK TRANSMISSION
COOLER INSTALLATION

3
4 6
2 5 7
1 The Direct Fit Transmission Cooler from

Flex-A-Lite comes with a cooler, necessary
hardware, hose, clamps, barbed fittings, and a
support. The kit comes with four self-tapping
screws to mount the bracket to the core sup-
port. We took the install one step farther install-
or may not have this arrow. The alternative is to
start a cool vehicle and drive it a short distance
and then assess the temp of the two cooling lines
bracket that makes fitting it onto a JK a breeze. ing 6mm rivnuts instead of the self-tapping either using your hand or a temp gun. The warmer
We started by mounting the cooler to the screws. This is not necessary, but does yield a one should be the one with fluid going from the
bracket following the included instructions. The slightly nicer final installation. transmission to the factory cooler.
bracket and cooler are made out of lightweight
aluminum and the hardware to mount the cooler
to the bracket is stainless steel. 5 From here we installed the supplied hose on
the cooler and fed it through and below the
radiator and radiator core support. You’ll have to
7 Once we checked and double checked to
ensure we would be cutting the correct
factory transmission line we trimmed the sup-
2 The next step is to remove the JK’s grille, a

comically easy task. First use a small flat
head screwdriver to remove the factory plastic
make your way under the Jeep to splice the hose
into the transmission coolant line that is feeding
the radiator mounted cooler. In order to maxi-
plied hose to length and prepared each end
with the supplied barb and hose clamps. You
can slide the second hose clamp onto the barb
retainers along the top of the grille. Pry up the mize transmission performance you want the flu- and tighten it enough so it won’t fall off making
center and the whole retainer should come out. id from the transmission to run through the Flex- it that much easier to splice these two hoses
A-Lite cooler first, then the factory transmission into the factory transmission line. With the two
3 With the plastic retainers removed from the

top of the grille a sharp yank will pop the grille
cooler, and then back to the transmission hoses pushed together move the last two band
clamps into place and tighten. We then started
loose from its remaining mounts. Then disconnect
the right and left running light from the grille. Set
the grill aside face up to prevent any scratches.
6 The supplied instructions tell you one way
to determine which line from the transmis-
sion is the one that has the hot fluid leaving the
the Jeep, got it to operating temp and topped
off the transmission fluid. Reinstall the grille
and go four-wheeling.
transmission. We also traced the lines back to
4 We then dry fit the cooler and bracket to the

radiator core support. You may want to pop
loose a few wire loom anchors along the top
the transmission where arrows on our transmis-
sion indicated the direction of flow. We marked
the arrow that indicates flow with a permanent
SOURCE
FLEX-A-LITE
of the core support. We then marked the four marker to give you an idea of what to look for. 800.851.1510
mounting points from the bracket onto the core Your transmission, depending on year model, may flex-a-lite.com
BY Trenton McGee Things changed when emissions con- back system used on 1982-1986 CJs.
cerns led to the arrival of electronics in the We recently received a call from a rela-
EDITOR@4WOR.COM
PHOTOGRAPHY TRENTON MCGEE early 1980s, when carburetors suddenly tive with a low-mileage 1986 CJ-7 that
D
became a maze of vacuum lines, solenoids, had quit running. While mechanics had
ON’T GET US WRONG. valves, and systems so complicated they are thrown plenty of parts at it, most of them
There’s absolutely nothing virtually guaranteed to fail. Computer-con- hadn’t been born when the CJ rolled off
wrong with a carburetor. trolled carbs are universally known for their the assembly line, and they failed to bring
These largely mechanical poor performance, crappy driveability, and the Carter system back to life.
devices have delivered pre- lousy mileage. While it could be argued that We rescued the Jeep from the techs
cise amounts of air and fuel modern fuel injection is a viable upgrade for more used to working with OBD-II ports
into engines from the very any carbureted engine, it is especially so for and resolved to fix the problems once and
first internal combustion engine until elec- a vehicle with anything more than a choke for all with a tried and true Howell throttle-
tronic fuel injection took over in the late wire going to the carburetor. body injection system. This stand-alone
1980s. Though tuning a carburetor is rap- While all computer-controlled carbure- fuel delivery system retrofits GM’s Throttle
idly becoming a dying art, they are a boon tors are bad, among the worst systems Body Injection System to a wide range of
to off-road enthusiasts for their simplicity. ever devised was the Carter BBD feed- engines across all makes and models. The
DRIVEWAY EFI
company manufactures a
Jeep CJ–specific system
that is 50-state legal, uses
all GM components, and
bolts in place. It sounded
like the perfect remedy for
UPGRADE
our Carter woes.
Here we cover installing the How-
ell system on a six-cylinder Jeep,
but most of the steps are similar
with any engine regardless of
displacement or arrangement. We
HOWELL FUEL INJECTION

installed the entire system in a few
days, mostly in the evenings after
work. We’re confident that any-
& DUI IGNITION one could install a Howell

kit in a weekend, or even
UPGRADES FOR
a single day with some
hustle. Along the way
we also upgraded the
OLDER VEHICLES ignition system and

took care of a pesky
oil leak, but nothing
we did required any-
thing other than simple
handtools. Though a
fuel injection system
is an investment, it’s
one of the most worth-
while upgrades you
can make to any
older 4x4.

1 Mom said if you can’t say something nice, say
nothing at all. Sorry, Mom, but this system
is all garbage. A puny computer-controlled
one-barrel carburetor with more vacuum hoses,
switches, valves, and solenoids than a current
model year fuel-injected engine that is choking
an otherwise excellent engine with less than
80,000 original miles on it. There is no reason-
able excuse to keep the Carter system, even if
you are a purist or subject to emissions laws.
CJ-7s fall outside the 25-year emissions exemp-
tion rule that have been enacted in most states,
and the Howell system is 50-state legal, carry-
ing a California Air Resources Board (CARB) EO
number that is recognized not only in California
but also in other states that have adopted the
same standards.
2 Howell makes specific EFI systems for a vari-

ety of vehicles, and its CJ system is a typical
example of just how complete all of the systems
are. Included are a self-contained wiring har-
ness, fuel pump, fuel filter, throttle-body adapt-
er plate, computer, speed sensor, oxygen sensor,
1 throttle body with injectors, fuel hose, a temp
sensor, and a MAP sensor. A small assortment
of hardware is also included, making this one of
the most complete EFI systems on the market.
3 It takes an hour or two to exorcise the Carter

BBD demon, but this is all of the stuff that
will soon occupy a garbage can. Virtually all
of the vacuum and wiring on the engine can be
removed, along with the carburetor and the
confounding number of switches and solenoids.
Luckily the wiring harness for the Carter system
was “added on” to the core CJ-7 harness that
was designed in 1970s, so the whole thing is a
subharness that can be eliminated by cutting
only a single wire (related to ignition). The car-
buretor’s computer resides on top of the heater
box behind the glovebox and should be removed
along with the rest of the carburetor wiring.
4 The adapter provided in the Howell kit con-

verts the fairly odd Carter bolt pattern on the
stock intake manifold with the equally odd bolt
2
pattern of the GM throttle
body. Gaskets for both sides
of the adapter and hardware
are included. The instruc-
tions suggest dabbing RTV
on top of the adapter bolts to
prevent vacuum leaks.
5 The Howell throttle body

is identical to what you
would find in a mid-1990s
4.3L V-6 in a Chevy S-10 or
1
⁄2 -ton truck. The throttle
body itself is remanufac-
tured, but all of the injectors
3
and sensors are new. The
4 nice thing about the Howell
system is that everything is
OE GM stuff, with not a single
aftermarket component.
This means that replacement
parts are common and avail-
able at any auto parts store.
It simply bolts to the adapter
plate, and it’s even set up for
the CJ throttle linkage for a
5 true bolt-on installation.
4-WHEEL & OFF-ROAD MARCH 2020 45

DRIVEWAY EFI UPGRADE
6 GM throttle body injection requires about

15 psi to run, while the original mechanical
fuel pump that fed the carburetor is only good
for about 5 psi. Therefore, the mechanical fuel
pump is no longer used and Howell includes
a block-off plate for the engine. We mounted
the new electric fuel pump to the inside of the
frame above the belly pan and made sure the
supplied filter was positioned between the
tank and the pump. We used the supplied hose
to route fuel to the throttle body and utilized
the original return line to the tank.
6 9
7 We decided to do something about the
leaky plastic valve cover before we started
stringing the Howell wiring harness across the
engine. Anybody who has owned one of these
Jeeps knows that getting the factory cover to
seal is almost impossible. People usually over-
tighten the cover and warp it, and it’s just a bad
design overall. This one was leaking just like all
the others. It was time to fix it once and for all.
8 We picked up a heavy-duty aluminum valve

cover from Omix-ADA. Not only does the
valve cover look a lot better, but it also pro-
vides a much more reliable seal than the origi-
nal plastic piece. Installing it on a later engine 7 10
like ours does require tapping two existing
holes in the head, but it simply bolts in place
on earlier 258s. It’s not a direct replacement
if you plan to retain the factory air cleaner,
as it doesn’t have the mounting studs for the
assembly like the original valve cover, but most
people choose to upgrade the air cleaner any-
way. We did have some challenges getting the
new cover to seal up, but check out the sidebar
for the solution that worked for us.
9 Since we were already upgrading the fuel

system, why not improve the ignition at the
same time? We opted to replace the stock stuff
with a Performance Distributor from Davis Uni- 8 11
fied Ignition. The distributor drops right in the
place of the factory distributor and uses GM
large-cap HEI technology with an integrated
coil and module. Installation is a simple one-
10 Along with the new distributor we also
installed a set of the company’s LiveWire
spark plug wire sets. These custom-fit wires
12-volt power, and there’s a tach output if your
Jeep is equipped with one.
wire hookup. DUI tailors the distributor curve

for your specific application. The company
had the proper curve on file to optimize per-
came labeled for each cylinder and even
included some cool aluminum wire separators.
We’re not 100 percent happy with our routing
11 The TBI computer is not sealed and needs
to be mounted in a place that will be pro-
tected from the weather and excessive heat.
formance with the Howell EFI system. Though of the wires and plan to play with them some We chose to mount the computer right where
quite a bit larger than the stock distributor, the more to see if we can end up with a cleaner the original computer used to be, on top of the
DUI piece installs with no modifications. look. The distributor itself only needs switched heater box behind the glovebox door. Even
VALVE COVER SEALING TIPS
S
ealing a 258 valve cover can be a real manufactured by Fel-Pro (PN VS50244R)
challenge, even when using an after- made specifically for aftermarket valve cov-
market aluminum valve cover. There’s a ers on 258 engines. The Fel Pro instructions
lot of gasket surface, the cover itself is really stated the gasket should be installed dry (no
long, and placing it on the head evenly is RTV), so we did. It leaked.
tricky while fighting various hoses and wires. On a tip from a friend, we cleaned up the
Truth be told, it took us three tries to get Fel-Pro gasket and reinstalled it with some
our valve cover to seal up. Our first attempt copper Spray-a-Gasket from Permatex. We
was with the cork gasket supplied with the sprayed the bottom side of the gasket and
valve cover, which we used with RTV silicone the valve cover but let them both sit for a
and let the engine sit overnight before firing few minutes so the sealant would get tacky,
it up. We’ve been told people have been suc- then carefully installed and torqued the
cessful with this method, but ours leaked. valve cover to 50 lb-in. Once again we let the
Attempt number two involved replacing the engine sit overnight. The third time was the
cork gasket with a special composite gasket charm, and our valve cover leaks no more.

A B
C
12 15 16
13
14 17
though the GM computer is slightly bigger than that’s hot in both start and run positions. computer uses to optimize a variety of differ-
the original Jeep computer, there was plenty of ent things. This is one of the many differences
room once we removed the factory computer’s
mounting bracket (which is riveted to the heater
box). We used some industrial Velcro adhesive
14 Like most fuel injection systems, the Howell
TBI relies on an O2 sensor to read and adjust
fuel mixture. Carter BBD–equipped Jeeps have an
between using a Howell system versus piecing
together your own system from junkyard compo-
nents. You won’t find one of these in a junkyard.
pads to secure the computer in place. exhaust manifold with an O2 port built in, so you
12 Wiring the Howell system may be the easi-

est part of the job. The harness is preter-
simply replace the old O2 sensor with the new one.
Older CJs don’t have this port, so a weld-in bung,
which Howell supplies, needs to be installed on
17 The finished product is much cleaner than
the original rat’s nest of hoses and wiring, not
to mention far more reliable. We topped the throttle
minated, and each lead is clearly marked where the exhaust pipe close to the manifold. body with a new 9-inch-diameter air cleaner and
it connects. We routed the harness from the then took the Jeep for a test drive. The improve-
computer through the firewall using the grom-
met from the original harness (A), and mounted
the master fuse, fuel pump fuse, and fuel pump
15 The vacuum hose routing is quite a bit dif-
ferent than the old carburetor but merci-
fully much simpler. Fifty-state-legal installations
ments could be felt right out of the gate, with better
throttle response, more power, and no more stum-
bling as soon as the Jeep was on an uneven surface.
relay (B) to the firewall just above the engine. need to retain the factory temperature switch Drivability continued to improve as the computer
We then plugged the harness into the various that controls the vacuum signal to the EGR and “learned” and idle became more stable. Not only did
sensors on the throttle body and hooked up the charcoal canister, but otherwise you simply we fix a pesky oil leak, but we breathed new life into
fuel pump. We mounted the MAP sensor to the hook up the distributor to ported vacuum (right an old Jeep in a single weekend.
firewall (C) near the brake booster using a simple port as you face the throttle body) and the PCV
L bracket. It’s important that the sensor be
installed with the vacuum port facing down and
valve unported vacuum. The Howell instructions
have a diagram that makes things pretty clear.
SOURCES
mounted within 12 inches of the throttle body. DAVIS UNIFIED IGNITION
901.396.5782
13 The Howell wiring harness needs just three 16 One of the most often overlooked por-
tions of a TBI conversion is adding a
performancedistributors.com
wires to be hooked to the vehicle: Constant speed sensor. The TBI uses the speed sensor to HOWELL ENGINE DEVELOPMENT
power, switched power, and start power. We calculate a variety of different things, from fuel 810.765.5100
hooked the constant and start leads to the hot curves to idle speed. The Howell system includes howellefi.com
and start side of the starter solenoid, and utilized this speed sensor that installs in line with the
OMIX-ADA
one of the original computer’s leads for switched mechanical speedometer cable. It converts 770.614.6101
power. It’s important to select a switched circuit the mechanical rotation into a signal that the omix-ada.com
BY Christian Hazel rockcrawler. Many are content to use their and Powerstep XL automatic, electric-
Jeep Wrangler as an everyday commuter powered running boards. The Powerstep
EDITOR@4WOR.COM
PHOTOGRAPHY CHRISTIAN HAZEL and weekend fun machine. After all, they keys into the door light switches and
T
are super-capable right out of the box. automatically extends to a lowered posi-
HE FOUR-DOOR WRANGLER However, some things that lend to tion when the door is opened and retracts
Unlimited has been a smash Jeep’s off-road abilities make it less than when the door is closed. For tall, lifted
hit from the day it entered the easy to live with on a daily basis. And vehicles, the Powerstep XL offers a 3-inch-
marketplace as a 2007 model. a high step-in height is definitely one lower stepping surface compared to the
Given the vast improvements of those things. We had a buddy who regular Powerstep, and is housed inside
the JL Wrangler brings to the just picked up a brand new JL Wrangler a custom rocker rail. For muddy, snowy,
table, it’s little wonder Jeep Unlimited, and while he absolutely loves and other harsh climates, there’s the
is still selling every four-door Wrangler the vehicle, it was difficult for his elderly Powerstep Xtreme, which is designed to
it can manufacture. But not everybody parents to climb into. Not to mention little hold up to heavy caking of snow, mud, ice,
who purchases a new JL Wrangler wants kids and even the dog. and other contaminants. However, for this
to immediately turn it into a hardcore Enter Amp Research and its Powerstep particular application, the regular Power-
IT’S NOT HARD TO ENTER EASY!

step proved perfect. Here’s how we added
some easy entry ability in an afternoon.
INSTALL AMP RESE

48
POWERSTEPS ON A
3
1 6
2 5 7
1
“ Not everybody is building a rockcrawler
”
Amp Research provides everything you need
for installation down to the wiring zip ties
and connectors. You’ll need regular sockets and
wrenches, Allen-head wrenches, and a crimp-
ing tool. We laid out the parts on our 1971 CJ-6 plates inside the boards are captured and slide the directions. A portion of the harness needs
workbench and got to it. fore and aft, allowing some adjustment in board to be snaked up through a drain hole in the
placement on the brackets. We measured from passenger-side front floorboard to access the
2 The first step is to install the brackets at the

indicated positions. There is absolutely no
drilling required to install the Amp Research Pow-
the rear tire to get the boards evenly positioned
on both sides of the vehicle.
door light wiring per the instructions.
ersteps on a JL Wrangler. The brackets install with

two bolts horizontally through the pinch seam 4 The electric motors index into the forward
brackets and are held in place with two
6 The interior harness connects to the four
door-open wires on the passenger-side kick
panel. Follow the instructions and match the
and one bolt vertically into the existing factory bolts. The instructions say to leave off the wire colors to factory. Once that’s completed,
running board mount. The small angled bracket motors and install after the running boards hook the interior harness to the wires that you
for the LED lamp should be positioned into place are mounted to the brackets, but access to the ran up through the floor drain plug, insert the
before the brackets are tightened down. driver-side motor bolts is very, very tight. If we fuses, and test for function.
were doing it over we would install the motor on
3 With the brackets mounted, the next step is

to hang the running boards on them and fas-
ten with the supplied hardware. The mounting
the forward driver-side bracket before mounting
it to the body. 7 The LED lamps attach to the bracket with
automotive-grade adhesive. When either
door is opened the step will lower and the light
EARCH
5 With the hardware cinched down we
installed the Powerstep wiring harness. The
harness comes preassembled in a protective
will illuminate. If you want to leave the steps in
the lowered position for loading, just put a little
pressure on it and it will stay deployed until the
loom and is nearly the prefect length out of the door is reopend and closed. Conversely, if the
box. Leaving the fuses out, we connected the step encounters resistance when trying to open,
power to battery, and ground to chassis, and it will retract back to the closed position to
ran the harness down to the electric motors per avoid damaging anything.
A JL WRANGLER
SOURCE
AMP RESEARCH
800.309.6823
amp-research.com

TECHNICAL
HOW
BY Harry Wagner things the long answer is considerably
more nuanced.
EDITOR@4WOR.COM
PHOTOGRAPHY HARRY WAGNER The first consideration is not the
W
amount of width but rather how you are
IDE-AND-LOW IS gaining it. We have seen Toyota pickups
WIDE
all the rage right running wheels with 2-inch backspacing
now, and it’s easy to and wheel spacers where the brake rotor
see why. The added isn’t even inside the wheel anymore. The
stability that comes solid axles under early Toyotas offer great
from running wider ground clearance and can be built to
axles and a lower handle 37-inch-tall tires, but they are only
IS TOO
center of gravity makes your 55 inches wide. While the 37s won’t break
vehicle more capable on the chromoly Birfields, they will be rubbing
trail, particularly in off-camber hard on the Toyota frame and leaf springs
situations. The new JL Rubicon during articulation and steering, limiting
has axles that are a full 20 inches the steering angle that is possible. Adding
wider than the axles under the width outside of the steering knuckle not
WIDE?
original WWII-era jeep MB and only adds leverage to the trunions (or ball
GPWs. The JL frame is also 17 joints) but also creates tremendous scrub
inches wider than a flattie frame as you turn since the tire travels in an arc
though, dictating some of that instead of rotating on the contact patch.
added axle width. Is there such A better choice is to swap in entirely
a thing as too wide though? The new axle assemblies that are wider than
short answer is yes, but like most stock. Consider that Dana’s Ultimate Dana
ARE FULL-WIDTH
AXLES RIGHT
FOR YOU?

60 axles that bolt in to JKs are 2 inches wid-
er than stock, and Dynatrac’s bolt-in axles
fit a coil bucket or control arm mounts. The
rear axle is much easier since the differen- 1 Running the tires outside of the body is a
great way to keep rocks away from your
sheetmetal. Unfortunately, it is also a great
for JKs are available either 3 or 5 inches tial is typically centered; we recommend
way to throw rooster tails of water behind you
wider than stock. The rationale is that if you finding the appropriate front axle and then on the street, so plan to add mud flaps or throw
need bigger axles you are likely running just getting a rear axle that matches the yourself on the mercy of the court when you
big tires. Basic trigonometry tells us that a width and bolt pattern of the front axle. No get pulled over.
40-inch tire will reach the frame at a lesser one runs a Sterling 10.5 over a GM 14-bolt
angle than a 35-inch tire. Wider axles not
only add stability but also improve steering
based on merit, but Sterlings are commonly
swapped in since they are the companion 2 Having the tires outside of the body makes
it easier to see them on the trail. This helps
you to see not only what you are hung up on
clearance between the tires and the frame, to Dana 60 front axles in Super Duty trucks. but also which direction the front tires are
steering components, and suspension links Even with the same wheel mounting pointed at any given time.
or leaves with metric 8x170 bolt patterns. surface (WMS) measurement between
Even with junkyard parts, axle swapping
is typically neither simple nor inexpensive.
two axles, the overall track width can vary
greatly. We recommend running wheels 3 Even with the same width axles, overall
width can vary greatly depending on wheel
backspacing. These Hutchinson double-bead-
Considerations include not only axle width with the maximum amount of backspac-
lock wheels are 8.5 inches wide but have 5.25
but also which side the front differential ing that still allows a full range of steering. inches of backspacing to keep the overall track
is on, the wheel bolt pattern, and the The added backspacing not only protects width reasonable.
placement of suspension mounts. With the brake and steering parts but is easier
leaf springs, it is sometimes necessary to
outboard the front springs to align with the
on the steering and knuckle components
as well. Any wider and you are just driving 4 These custom axles were built to be 63.5
inches wide to allow the use of off-the-
shelf RCV axles instead of having to order
spring perches or narrow the axlehousing over obstacles that you could otherwise
custom axles. The axleshafts not only dictated
(and axleshaft to match). Coil springs can drive around. Like most things in life, add- the overall width but the position of the third
present an even greater issue if there isn’t ing axle width the right way isn’t necessar- member relative to the ends as well.
enough room on the short side axletube to ily the easy way.
1 2
WIDE AXLE PROS

• Stability
• Full lock steering
• Keep body off rocks
WIDE AXLE CONS
• Fitment between obstacles
• Flinging mud
• Street legality 4
HOW WIDE IS TOO WIDE?
ULTIMATE COMFORT FOR YOUR
OFF-ROAD ADVENTURES
T E RRA IN
SERIES
BO M B E R X T RS EM E
ERIES
SERIES
1620 1630 1700
1400 KINGSDALE AVE. REDONDO BEACH, CA 90278 /// P (310) 370.5501 /// F (310) 214-2285 /// WWW.PROCARBYSCAT.COM
STUCK IN A RUT? Get out with the DON’T GET STUCK 5 Don’t do this. Please, we are begging you.
Running wheels with shallow backspacing
WITHOUT THEM! is hard enough on steering and suspension
parts, but then adding spacers just makes mat-
ters worse. We don’t want to see your rotors, or
your powdercoated wheel spacers.
Now with AmSteel®Blue Rope!
THE FOLDABLE LAND ANCHOR
t4USPOHFSUIBODBCMFoOPXJSFXJDLFST
tQPSUBCMF 970.963.4507 • pullpal.com 6 Toyota axles are 3 inches wider than
Samurai axles, making them a worthwhile
upgrade. The narrower frame of the Samurai
t-FTTFYQFOTJWFUIBOBXJODI LEARN
tUPOEFBEMJGUUPOESBHSBUJOH TO WELD
(compared to a Toyota) allows for full steering
XJUIGUSPQFNPEFM ® DVD lock, even when running 37-inch-tall tires.
t1VMMGSPNGSPOU SFBSPSTJEF
"-40
"7"*-"#-&
Made of solid iron and steel! ONBOARD WELDER 7 Sometimes narrow axles will allow you to
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*/45&&- ."/6'"$563&%4*/$&#: 970.963.8875 • premierpowerwelder.com
ORDER
$"#-& width would require you to go over. Other
.0%&-4 The Wyeth-Scott Co.
times, though, the narrow axles work against
TODAY!
t
wyeth-scott.com /FXBSL 0IJPtTBMFT!XZFUITDPUUDPN you, such as in off-camber situations like this.
8 Super Duty axles are perhaps the most

commonly swapped axles due not only to
their width but their wide availability, strength,
and low price, too. One issue when using older
leaf sprung Super Duty axles is the lack of
material on the short side axletube, making it a
challenge to add suspension mounts.
9 This Jeep is running 42-inch BFGoodrich

Krawlers on 20-inch Raceline beadlocks.
Not only would the factory axles break when
running such a large tire, but they would also
be too narrow to allow full steering lock. The
Ultimate Dana 60 crate axles solved both of
those problems by being much stronger as well
as 2 inches wider than the stock axles.
10 The shock mounts on Wranglers hang

down well below the axletube, but since
they are right next to the tire, they rarely
impede progress on the trail. The farther the
tires are away from the differential, the more
likely you are to catch the diff on a rock.
11 Full-width axles under a Toyota pickup

leave a lot of tire outside of the body.
This can come in handy when you fall into
a crack or are dragging the truck through a
notch like this one.
9
Jeep, AMC 4x4s
"ENEÜTFROM$5)
Distributors too!
Off-road purists rely on Jeeps. And
more Jeeps rely on D.U.I. one-piece
ignition systems. With its one-wire
hook-up, dual bushing design, and
resistance to mud and vibration, the D.U.I.
distributor is both simple and bullet-proof…and
its performance is unmatched: super hot spark
for wider plug gaps (to.055-inch); 50,000 volt coil;
Dyna- Module; Available for all Jeep/AMC 4x4
6-cylinder or 8-cylinder powerplants.
$5)4ECHNOLOGYFORBOTH
7 Toyota LandCruisers &
Toyota 4-Cylinders
It’s only natural that D.U.I. adapts
its unique distributor technology
to the popular Toyota LandCruiser.
The Toyota D.U.I. distributor
features the same battle-
tested components as its
GM and Ford counter-
parts: coil inside the cap,
module inside the distri-
butor, and one-piece design
for quick installation and service.
8 10 VW D.U.I
for VW Type 1 motors. The all-in-
one design of the DUI makes it
ideal for VW engines that are put
through extreme conditions. The
DUI will withstand mud, water,
sand, and vibration! The D.U.I.
is a one-piece, one-wire distributor. The D.U.I.,
which is fully electronic, eliminates the hassles of
changing points and makes for a much cleaner
installation than other aftermarket systems that
make a maze of messy wiring.
LS SOS Coils
‘99-’15 Silverado/Suburban/Tahoe/
GMC Whether you’re running a
Silverado,Suburban, Tahoe or
a GMC with a LS Vortec truck
engine,we have a set of S.O.S.coils
for you. Dyno-tested 15-25 more
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Chevy D.U.I.. Distributor

The Chevy D.U.I. Distributor is
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11
FEATURE
N THE PAST, DESERT RACERS AND the spot on the Venn diagram where these rig, such as solar panels, drawers, a fridge,
prerunners added long-travel two worlds overlap, and you will encoun- and a headliner covered in patches.
suspension and bypass shocks to ter Jason Berry’s Tacoma. The truck is no slouch in technical terrain
conquer whoops and silt beds but This Double Cab Tacoma has Total either. Jason added a Currie Enterprises
typically returned to their hotel Chaos long-travel front suspension, rear F9 rear axle and 4.88 gears with ARB Air
or trailer at night. In contrast, Deaver leaf springs, and King bypass Lockers front and rear. The fenders were
overlanders lumber along slowly shocks. It also has a Vagabond Outdoors trimmed 2 inches to allow fitment of
with their heavy suspension, enjoying the Drifter camper and the usual components 35-inch Cooper Discoverer STT Pros with
destination more than the journey. Find you would expect to find on an overland full suspension travel and a low center of
TACOVERLANDER
gravity. Relentless Fabrication skidplates,
rock sliders, and bumpers fend off hits from TECH SPECS
rocks and other obstacles on the trail.
Oh, and did we mention that it has a 2012 TOYOTA TACOMA Discoverer STT Pros on 17x8.5 Method 105
beadlock wheels
supercharger to offset all that added DRIVETRAIN STEERING: Stock rack, extended tie rods
weight? Jason Berry has built a Tacoma ENGINE: Supercharged 1GR-FE 4.0L V-6 LIGHTING: FXR HID Retrofit headlights, Rigid Indus-
TRANSMISSION: 5-speed automatic tries 40-inch Midnight LED Roof Bar, Rigid Indus-
that can go just about anywhere, and get TRANSFER CASE: Factory chain drive tries SR2 20-inch combo driving and Hyperspot
there in a hurry. FRONT AXLE: Toyota 8-inch IFS with 4.88 gears LED bar, Rigid Industries D2 Dually lights
and ARB Air Locker OTHER STUFF: Vagabond Outdoors Drifter camp-
REAR AXLE: Currie 9-inch with 4.86 gears and er; SOS Performance big brake kit (front and
LONG TRAVEL ARB Air Locker rear); MBRP exhaust; Weathertech floormats;
Wet Okole seat covers; Kenwood ham radio;
SUSPENSION Warn Zeon 12-s winch; Prinsu CabRac roof
FOR THE
SPRINGS & SUCH: Total Chaos +2 suspension rack; Relentless Fabrication front bumper, slid-
with King coilovers and bypass shocks (front); ers, and high clearance rear bumper with swing
Deaver leaf springs and King bypass shocks out tire carrier; two 100-watt solar panels;
LONG HAUL
and air bumps (rear) ARB drawer; Alu-Cab fridge slide; ARB 82-quart
TIRES & WHEELS: 315/70R17 Cooper fridge; Airflow snorkel; ARB dual air compressor
BY Harry Wagner
EDITOR@4WOR.COM
TACOVERLANDER
1 Power comes from the original 1GR-FE V-6

engine that has been upgraded with a Mag-
nuson supercharger, URD Y-pipe, and MBRP
cat-back exhaust. From there the factory five-
speed automatic routes power to the original
two-speed, chain-driven transfer case. Jason
Berry has considered adding dual transfer
cases but hasn’t felt the need to do so yet for
the type of wheeling he does.
2 The front suspension uses Total Chaos

chromoly control arms that are 2 inches
wider per side and use 1-inch uniballs between
the factory spindles. The OEM CVs are retained,
but used with extended chromoly axles and
CV boots from SDHQ that allow for increased
angularity without tearing. The King coilover
shocks are fitted with 700 lb-in coil springs and
supplemented by an 8-inch-travel King three-
tube bypass shock that Jason tuned himself. 1 7
2 3
3 Relentless Fabrication is based out of Reno

near Jason’s Tahoe home, and he used the
company’s products on his previous Tacoma as
well with great success, so it was a no-brainer
when it came time to outfit this truck. Relent-
less products include the high-clearance rear
bumper that features a swing-out tire carrier
and side protection for the bed, as well as the
rock sliders, front bumper, and skidplates.
4 The factory 8-inch rearend was replaced

with a 68-inch-wide Currie Enterprises F9
with 31⁄2 -inch axletubes. The third member is
nodular iron and has 4.86 gears and an ARB Air
Locker. The axle uses Toyota outers and bear-
ings and a SOS Performance rear disc kit with
StopTech four-piston calipers.
4
5 Jason swears that he isn’t one of those
stereotypical overlanders, but the patches
on the headliner suggest otherwise. Functional
interior upgrades include the Weathertech
floor mats, Wet Okole seat covers, Kenwood
ham radio, and OTRATTW switches.
6 The rear suspension uses custom Deaver leaf

springs on BAMF shackle hangers. King air
bumps work in conjunction with King 12-inch-
travel, three-tube bypass shocks on custom
mounts. The truck had a shackle flip with com-
pression shackles when Jason bought it, but he
returned to the inverted shackle configuration
5 6 to improve the ride and allow for more uptravel.
“ This Tacoma can do
just about anything
”
8 9
7 The Tacoma has been customized to allow

Jason to enjoy multiple daytrips into the
backcountry. The suspension soaks up wash-
board roads, and the Vagabond camper is a com-
fortable place to sleep. The bed of the truck has
been set up for cooking and camping—the only
thing left to do is build a campfire.
8 Jason set up the swing-out for the rear bum-

per with a folding table that holds a Camp
Chef two-burner stove. Between this and the tail-
gate he is able to easily whip up gourmet meals on
the trail. All of the cooking gear goes in the ARB
drawer under his 82-quart ARB freezer-fridge.
11
9 The headlights are FXR HID retrofits by
Ambiguous that use Osram 4,300kw bulbs.
Jason also has a host of Rigid Industries LED 10
lights, including D2 Dually driving lights, D2
amber fog lights, D2 reverse lights, a 20-inch
combo driving/spot light bar in the front bum-
per, and a 40-inch Midnight Series light bar on
11 The Vagabond Drifter uses a 3-inch-thick
memory foam mattress and has enough
space to allow pillows and bedding to be left in
the roof. He has no problem turning night into place. A ceiling fan and zip-out windows provide
day on the trail. plenty of ventilation when it is warm but can
also be sealed up for adverse weather.
10 Dual Optima YellowTop batteries were

relocated to the bed and secured with a
Trail-Gear battery tray. Under the hood the origi- 12 Jason opted to have Front Runner
hard side windows on each side of his
nal battery location now holds a Blue Sea fuse Vagabond Drifter. These windows provide easy
panel, battery isolator, and 100-amp breaker. access to the contents of the bed while also
Two 100-watt solar panels sit on the roof of being lockable and completely sealed from the
the Vagabond camper and charge the batteries elements. They are actually designed for a Land
through a Renogy Adventurer solar controller. Rover Defender but fit perfectly on the camper. 12
TECHNICAL

BY Verne Simons 1
I
DIOMS ABOUND. THEY SAY THAT
necessity is the mother of inven-
tion, and while that may be true,
being a cheap bastard also some-
times helps you build stuff inexpen-
sively that might just work(?) As a
rule we don’t like throwing things
away unless they are really and truly used
up. Take for example the old engine hoist
we had sitting around the shop for years
collecting dust because it was slightly
broken. Specifically, one of the heavy-duty
metal wheels was broken. While we’d tried
to get a replacement, those attempts
proved fruitless. The result was about 95
percent of a folding engine hoist—not
enough to use as intended, but enough
to cause much pause when it came to the 4
thought of its disposal.
Then, as luck would have it, we needed
an engine hoist on short notice, so we
2
1 Our focus group for testing out the idea of our
version of the yard crane was Hank the dog,
a 2-year-old mixed breed mutt who is a genuine
replaced said nearly perfect engine hoist
good boy (most of the time). One thing is for sure:
with its boogered wheel with a nearly iden- Hank’s front feet are always ready to make a turn,
tical replica of itself. Still, we couldn’t get right or left, and he is always happy. We think this
rid of the first hoist, thinking that if nothing crane thing might actually work. Our plan was to
else, its parts may one day be useful. Psy- take this length of 2x2-inch square, 0.250-wall
chologists, pay attention. This may be the tubing and make it one with the main beam of the
crane. Sometimes clamping things together helps
way hoarding problems get started.
determine whether an idea will or will not work.
Hoarders, rejoice! With an idea, a welder,
some scrap steel, and a saw, we have fol-
lowed through on a dream of anyone who has 2 First, we disassembled the hoist to make
some cuts. For the hoarders amongst us, don’t
worry—we’ll keep all the extra parts for spares
ever stubbornly retained something in hopes
that it may one day become useful again. for our other engine hoist. Our plan was to keep
the main beam at about the same angle as it was
Here’s how we turned a broken 2-ton engine
while it was an engine hoist. We also wanted to
hoist into a 11⁄2 -ton yard crane (we are derat- trim down the base because it would only add
ing it slightly for safety’s sake) for moving weight and not help with usefulness of the tool.
heavy items (of our hoard) around the yard. 3
3 After a couple of cuts we started to have
WORK SMARTER AND RECYCLE

something that, at least in our minds,
resembled the crane we were going for. We
VERNE’S
decided that the two bar straps that ran down
each side of the main beam of the engine hoist
were important for lateral (side to side) stability,
so we added some square tube and reinstalled
them. The extra pieces of these straps were
repurposed into gussets to make triangles,
which our engineer buddies tell us are strong.
BACKYARD
4 Here you can see all the 2x0.188 strap gus-
sets we added to the base of the crane.
We think it’s prudent to derate the unit from 2
tons to 11⁄2 . Aw, heck, maybe even 1 ton. Truly
though, our plan is to use it to move axles,
engines, transmissions, and transfer cases
around the yard and off our trailer.
HILLBILLY CRANE
BY Verne Simons
T
HE OLD-SCHOOL LEVER ON
the steering column or simple
aftermarket floor shift that
says “PRNDL” just won’t cut
it when it comes to shifting
these modern multi-overdrive
automatic transmissions,
which can be set up to hold a gear or
shift when directed. Ranging from 6L80,
SHIFTY
SHIFTY
AUTOMATIC ELECTRONIC
SPORT MODE SHIFTER
1
6L90E, 6R80, 4L80E, AODE, and 4R70W, units, requires an electronically shifted Our solution was to reach out to Lokar
shifting is down to you, whether you want controller (we have one from US Shift, sup- Performance Products for one of its
to simply select “D” and let the transmis- plied by Performance Automatic, which we Automatic Electronic Sport Mode shift-
sion shift in full-auto monkey mode or you have yet to play with since the truck isn’t ers, specifically one designed to work
want to toggle the gears yourself. The days running yet). It also requires a mechanical with the mechanical and electronic
of the promised paddle-shifted automatic shifter to act as an interface between driv- aspects of the Ford 6R80W transmission.
in the aftermarket is here. er, electronics, and mechanical selections We installed the shifter and are very hap-
Our 1969 Bronco project has just such a made within the transmission. So what do py with it so far, but as the project comes
transmission behind our BluePrint Bronco we do? We could repurpose some factory to an end we will also report back on
Edition 306ci V-8. The transmission is a parts to serve as this interface, but with a how the shifter and transmission work
2011 Ford F-150 6R80W built and adapted truck, and one with a retro feel, a shifter on- and off-road. For now, check out our
to the engine by Performance Automatic. from a late-model Mustang would seem installation of this tricky Lokar shifter
This transmission, like many newer auto out of place. with evergreen good looks.
5
4
2 Next we mocked up the supplied shifter brack-

ets and shift cable underneath the Bronco. It
became apparent that the shifter is intended to
be used on a two-wheel-drive 6R80 or at least
a 6R80 attached to a passenger-drop transfer
case. The issue is the cable and the mechanical
shift output are on the driver side of the trans-
mission, an area that will be very popular with a
spinning driveshaft coming from our Early Bronco
Dana 20. We realized that moving the cable to 6
the inward side of the supplied Lokar shift brack-
et and modifying the cable bracket slightly would want to keep the cable as straight as possible
make everything work together. To start, we cut on its run from the transmission to the shifter.
the cable bracket as shown. We did the best we could, given the layout of the
transmission and Early Bronco Dana 20.
3
3 We then rotated the trimmed bit of the
bracket 90 degrees and tacked it in place
6 Up top, the cable then heads directly for
1 With the Lokar shifter out of the packaging,

we began getting a feel for where the unit
would need to sit. This shifter is a modular unit
as shown (left). This allowed us to test-fit our
parts to see if the modified parts would work. It
turned out that the tab with the hole that holds
the back of the shifter. It is retained on the
leg sticking off the back of the shifter using a
supplied bolt and bracket. We are not sure how
intended for custom applications. That means the cable needed to be bent slightly (maybe much, if any, fine tuning we will have to do on the
that the mounting feet can be moved around 10 degrees) past 90 as shown (right). With the shifter to make sure that everything is where it
for various mounting configurations. All along modified bracket TIG welded up, we climbed should be, but for now the shifter moves through
we’ve been planning to use a floor-mount shifter back under the Bronco and mounted the new tab the gears wel, and the stops in the shifter seem
on top of the Bronco’s transmission tunnel using to the transmission using the supplied hardware to be right where they should be. The feel is as
some 1⁄4 -20x 3⁄4 -inch Grade 8 bolts and some 1⁄4 - and spacers, and then we installed the cable. sturdy and firm as you’d want it. Once everything
20 nutserts mounted to the transmission tunnel is wired up, we will be able to drop the shifter
cover. Any shifter will have to sit toward the pas- from “D” to “S” and then bump forward to upshift
senger seat so the twin-stick Dana 20 shifters
will have space to live. Unfortunately we are not
4 Here’s the cable mounted to our modified
cable bracket and bolted to the inside of the
supplied Lokar gear shift lever using the supplied
and backward to downshift. This should be help-
ful on the trail and on the road should we get
absolutely sure where the T-case shifters will rod end. The new bracket allows the cable to duck involved in any friendly stoplight drag racing.
end up, so we are giving ourselves some extra around the driver drop front output of the Dana 20.
space. If we need to move the shifter farther SOURCE
to the passenger side, we should be good. The
pigtails will be wired up to tell the transmission
how to shift when in sport mode.
5 From there, the cable runs around the trans-
fer case, skirts to the side of the rear output,
and goes through a hole drilled in the floor. You
LOKAR PERFORMANCE PRODUCTS
877.469.744
lokar.com
FEATURE
SLICKROCK
TRAIL
HIGH SIERRA OASIS

BY Harry Wagner If the name makes you think of Moab,
you aren’t alone. This Slickrock Trail is
EDITOR@4WOR.COM
PHOTOGRAPHY HARRY WAGNER located off the beautiful and circuitous
Highway 4, above Angel’s Camp in North-
LAYING HOST CAN BE ern California, though it’s a popular area
exhausting, for example when for wheelers from Modesto and Stockton
your in-laws are coming to looking to escape the summer heat up
town for Thanksgiving. Some- at the 7,300-foot elevation of the trail.
times, though, it is fun to be While only 5 miles long, Slickrock offers
host, like when your friends amazing scenery and some of the best
come to town to go rockcrawl- campsites we have ever found. Also, the
ing. For the last several years, a group of Forest Service recently added a new sec-
friends (including fellow contributor to tion of trail, including an optional rock
4WOR Brian Sumner) have made it a tradi- garden, at the north end of Slickrock to
tion to go rockcrawling and camping for reroute around private property. This sec-
this author’s birthday. We try to go to a new tion definitely increases the challenge of
trail in the Sierra Nevada Range each year, the trail, which is exactly what our guests
but after tackling the Rubicon, Fordyce, were looking for on their visit to town.
and Barrett Lake we had to look for other Now, where to go next?
options. That led us to the Slickrock Trail.
SLICKROCK TRAIL
1 2
1 This optional rock garden was recently

added to the north end of Slickrock by the
Forest Service. We are encouraged by the
agency’s commitment to shared access and
willingness to open up new terrain to motor-
ized recreation.
2 Slickrock can be run from north to south or

south to north, although it is arguably more
difficult going north. We actually ran the trail
both directions and camped along the way for
the night to maximize our time in low range.
4
3 This steep ledge is found at the southern

end of the trail. Like much of Slickrock,
there are several different lines varying from
easy to hard providing a challenge to any
vehicle and driver. This was definitely the more 3
adventurous route down the obstacle.
4 The Slickrock Trail gave us the opportunity

to test out Skyjacker’s new dual-rate coil
springs on our LJ. These coils are available in
a variety of lift heights for TJs, JKs, and JLs.
In addition to the superb ride, we appreciated
how much droop the 21⁄2 -inch lift springs had
without the coil coming out of the bucket.
5 We caught Andrew Vincent was out shak-

ing down recent upgrades to his FJ80 Land
Cruiser. He added a 6-inch lift from Slee Off
Road, Yukon Zip Lockers, and 37-inch Pro Comp
A/T Sport tires to his Toyota. The combination
worked flawlessly, not only on the trail but on
the drive to and from the trail as well.
6 The reroute of Slickrock was necessary

since the trail previously crossed private
property, which has since been developed
by the land owner. The new section of trail
includes a climb that still has a lot of small,
loose rocks on it that want to roll out from 5
under your tires. Low gear like the Offroad
Design Doubler in our 1977 F-150 make it pos-
sible to get to the top of the hill without spit-
ting out the rocks.
7 Our friend Phil Villanueva joined us in his

sweet solid-axle Toyota pickup on 37-inch
Interco TrXus M/Ts. These are one of the few
37-inch tires that you can still get for a 15-inch
wheel, and Villanueva says he has been very
happy with how the tires perform on the street
and the trail. Driving up Highway 4 to Slickrock
was a 35 mph, 4,000 rpm, Second gear ordeal
for the truck, but Villanueva said it was totally
worth it to get out on the trail. 6 7
8 The first time we rack Slickrock we did the entire
trail in a day, which isn’t impossible given the
short length. If you don’t stop and camp along Silver
Creek (shown) or Duck Creek you aren’t really mak-
ing the most of your trip in our opinion.
9 The Vagabond Camper on the back of Phil Vil-

lanueva’s Toyota pickup pops up in a matter of
seconds to make a home away from home. In addi-
tion to a bed, the wedge trailer also allows enough
room to stand up in the bed of the truck when you
need to change clothes or get out of the elements.
8 9
10 We don’t want to give you the impres-
sion that Slickrock is only for hardcore
rockcrawlers. We didn’t see anyone trailer their
vehicles to the trail, which is wise given how nar-
row and twisty Highway 4 is. Plus, every trail is
more fun in a little flatfender.
11 The great thing about Slickrock is that there

are several areas with different lines to chal-
lenge built rigs while allowing smaller vehicles to
still pass through unscathed. We appreciate that
this allows friends to all go wheeling together
without anyone getting bored, even if their vehi-
cles have different capabilities.
10 11 12 There are some epic campsites along Slick-

rock Trail, with our favorite being the ones
along these granite slabs at Silver Creek. Even on
a July weekend we had our pick of campsites and
there were only a few other people around. We
didn’t bring our poles but heard several reports
of people pulling fish out of nearby Lake Alpine.
13 We got some grief about our “pretty Jeep,”

but Brian Sumner drove it through Slickrock
Trail without spinning a tire. This LJ is a bit of a
sleeper with the AEV Conversions Highline Kit that
looks factory but allows the fitment of 37-inch
Falken Wildpeak M/Ts with only a 21⁄2 -inch lift.
14 Slickrock was pretty tight for our fullsize

Ford truck, but Bradd Davidson got the pick-
up through the trail unscathed. The wide sheetmet-
al not only makes navigating the truck through the
trees a challenge but also hinders visibility. Taking
12 it slow and using a spotter were key on Slickrock.
“The Forest
Service added
more obstacles
”
13 14
FEATURE
BY Harry Wagner less. After taking an oath of secrecy about through the book and make a rough plan of
the location for Ultimate Adventure 2019, what we wanted to stop and see and where
EDITOR@4WOR.COM
PHOTOGRAPHY BRIAN SUMNER my friend Brian Sumner and I took eight we wanted to go for the night. Each day we
AND HARRY WAGNER days to drive from Reno to Wasilla a month covered around 400 miles, which we felt
M
prior to the start. Tech Editor Verne Simons was necessary in order to complete the
E: I’M GOING TO DRIVE and I had previously driven my 1977 F-150 3,000-mile trip in a reasonable time and still
my truck to Alaska (dubbed Raymond, since everyone loves it) allow for some sightseeing.
this year for Ultimate 2,300 miles to Cabo San Lucas and back, Other participants traveling to the UA
Adventure! so I wasn’t too worried about the reliability swapped drivers and drove straight to
EDITOR HAZEL: Yeah, of the truck, just wearing out 42-inch-tall Wasilla, arriving drained for the exhausting
lots of people are doing tires and feeding the thirsty 460 engine a week ahead. Then they turned around and
that. Trent already steady diet of 91-octane premium. drove straight home! When you own a busi-
drove the Rover up to prerun the route. We started on familiar territory, north ness or only get two weeks of vacation a
ME: Oh, but I’m going to drive a truck from Reno through Bend and on to Portland year, there aren’t many other options. But
with a big-block! on a path I have taken many times. From we did have options, at least on the drive up.
EDITOR HAZEL: Yeah, the Watsons are there we made our way up the interstate My plan was for crony Ken Smith, who
driving their shop truck with a 454 in it. and crossed the border at Abbottsford, drove the Ford on UA, to drive the truck
ME: Oh, but I am doing it on 42s! where the route became less familiar. My back to Reno after the event. Things took
EDITOR HAZEL: Yeah, the Messers are copilot, Brian, was armed with The Milepost, a turn for the worse when we hydrolocked
driving up their Cherokee on 42s. a book that provides details about stops the engine on a particularly deep water
So maybe this trip wasn’t as unique as I along the Alcan Highway in startling detail. crossing in the Eureka Trail System. Ken
had hoped, but it was memorable nonethe- At the end of each day we would look knew better than to try and start the
ULTIMATE
TO ALASKA
& BACK
THE HARD WAY
66
(MIS)ADVENTUR
Starting the Cassier Kluane Lake is the largest lake in the Yukon
Highway in Gitwangak you Territory, and along its shores the U.S. Army built
really start to feel like you a road during World War II. Or more appropriately
are in the northern terri- tried to build a road, as they were unfamiliar with
tory. Authentic totem poles the freeze-thaw cycles of the area. Here you will
line the streets of Gitwan- also find the ominously named Destruction Bay. We
gak, and we encountered were fortunate to pass the area without incident.
First Nation peoples fishing
for salmon with dipnets. We alternated camping and cooking with
The huge totem poles hotels and dinners at restaurants in order to
dwarfed our Ford truck. keep the budget reasonable. Each night we
would lay out a plan for the next day regarding
which stops we wanted to make, where we could
purchase fuel, and how far we planned to go.
Boya Lake is a British Columbia provincial park known for its

sparkling clear water. The lake bottom consists of marl, which is
a combination of silt and shell fragments that are white in color.
You can rent canoes here and hike around the lake to fish and find
beaver dams. We could have easily spent all day at Boya Lake.
engine. After we were winched out of the the truck still wasn’t back together.
river, he pulled the plugs to get the water I had considered shipping the Ford to
out and changed the oil. Everything was Seattle on a barge, but it had to be running
fine for the rest of the trip, until the last day. to do that. Although the truck wasn’t run-
LA Speed built the 460 with hydraulic ning, the clock was, so with few options left
roller lifters from Comp Cams, and one of the I hooked an empty trailer behind my Ram
lifters got water in it during the submarine and drove north. I made it to Wasilla in three
impression. It operated fine until lack of days, and Cole had got the 460 running so I
lubrication killed the lifter. Swapping a lifter didn’t even have to winch it onto the trailer.
isn’t a huge deal…unless there are no parts I was drained, though, from driving 16 hours
to be found. Ken ended up driving the orange a day and sleeping in my truck, and I still had
double-ended JK back from Alaska, and UA to get home. Another good friend helped me
RE
attendees Frank and Cole Wininger were out (there’s definitely theme here) by flying
nice enough to let me leave the truck in their into Anchorage at the last minute and driv-
shop. Cole even offered to fix the Ford for ing back to Nevada with me. David Wiggins
me since he shares my affinity for these old didn’t get to spend eight days sightseeing,
Blue Oval trucks. After taking a week off for but he still got to experience the Alcan
UA, though, the Winingers got busy at their Highway and see plenty of the breathtaking
drilling company, trying to get caught up on scenery and wildlife that drew us to Alaska
work before winter hit. I was worried about in the first place. To quote The Beatles, “I get
winter as well, and at the end of September by with a little help from my friends.”
ULTIMATE (MIS)ADVENTURE
We backtracked a few miles on the Alcan after
finishing up the Cassier Highway to check out
the Signpost Forest in Watson Lake. We assume
the town is named after Stephen Watson from
Offroad Design, but no one could confirm this for
us. Do you see a sign from your town in there?
We hadn’t seen any wildlife on our trip

until we started on the Cassier Highway, and
then we saw four black bears in a span of 20
kilometers. Off the Cassier Highway we vis-
ited the town of Stewart, which is known for
its abundance of bears.
“Then things
got complicated
”
The cavalry arrived in the form of David Wig-

gins. A firefighter in Elko, Nevada, David had
Johnson’s Crossing is the southern terminus of the Canol Road, which was built during World some free time and booked a last-minute ticket
War II to transport oil from the northern territories (Canol is a portmanteau of Canadian oil). The to Anchorage to help us drive home. We won’t
southern 200 km of the road is a beautiful gravel road, while the northern 200 km has fallen into say that we couldn’t have done it without him,
disrepair. We hear it is impassible, but we want to go back and find out for ourselves. but we certainly wouldn’t have wanted to.
We added
a new intake
before the UA
that feeds air
from behind
the grille. We
thought it was
high enough
for water cross-
ings, but we
were wrong.
Ken Smith
pulled the plugs
and changed
the oil, but we
ended up losing
a lifter on the
last day due
to lack of
lubrication.
Alaska is such a rug-
ged and beautiful state,
and despite making mul-
tiple trips this summer
we still only scratched
the surface. We will
definitely be back again
to explore more of the
mountains, glaciers, and
mining towns.
Dense fog made for

slow going for much of
our drive. Between roads
we were unfamiliar with,
towing a trailer, and
wildlife on the roads, we
slowed to a crawl until
While the rescue trip was a mad dash, we did take time to stop at Liard the fog lifted. This was
Hot Springs for a relaxing soak. Copilot David Wiggins is a hot springs frustrating since we were
aficionado, and this was a condition of his before he would fly up to share on a short timeline, but
driving duties. A provincial park, the hot springs are affordable and very we certainly didn’t want
nice. You can even camp at the park. to risk an accident.
The sunsets were beautiful on our return trip, they just came way too
early in the day. We prefer to drive during daylight hours, particularly when there is
wildlife on the road, but the short days in October meant that we had to drive at night.
Going 50 mph pulling a trailer felt like we would drive for hours and not get anywhere.

THOR A-PILLAR GRAB HANDLES
Trail Head Off Road offers a universal
A-pillar grab-handle kit. It mounts sol- OFFROAD DESIGN PERFORMANCE GM BUSHINGS WITH KEVLAR
idly to the vehicle’s A-pillars using the Offroad Design (ORD) now upgrades its GM truck suspension and steering systems
kit’s included Rivnuts and hardware. with exclusive Kevlar-reinforced polyurethane bushings and steering end boots. ORD
The handles are designed to include chose the formulation because Kevlar is reputed to double material strength for greater
assist ingress, particularly in lifted split-resistance and longer wear under load. The new material is standard in all ORD
unibody vehicles. INFORMATION: THOR, crossover steering systems, HD shackles, and greasable spring bushing kits. INFORMA-
trailheadoffroad.com. TION: Offroad Design, 970.945.7777, offroaddesign.com.
G2 1350 JL DRIVESHAFTS
G2 now offers 1-ton-rated driveshafts with 1350-series U-joints for new Jeep JL Wran-
glers. They are designed to operate at up to 32 degrees of angularity. The shafts are made
from 23⁄4-inch-diameter DOM tubing and include solid-body 1350 U-joints. Each shaft is
dynamically balanced to eliminate vibration. Front and rear applications are available for
all JL models. INFORMATION: G2 Axle & Gear, 877.852.7720, g2axle.com.
SST TREMEC TR-4050 SWAPS

Silver Sport Transmissions (SST) offers
PerfectFit transmission swap kits for a vari-
ety of applications. The Tremec TR-4050
CASCADIA JK HOOD SOLAR PANEL SMITTYBILT STRYKER five-speed kit for Jeep Wranglers includes
Cascadia 4x4 offers a 100-watt solar WRANGLER REAR BUMPER the transmission, bellhousing, pilot bush-
panel kit specifically designed to fit the For Jeep JK and JL Wranglers, Smit- ing, flywheel, clutch, transmission mount,
hood of 2007-2018 Jeep JKs. The low- tybilt offers the Stryker rear bumper. shifter and tower, hardware, fluids, and
profile solar panel is only 3 mm thick. Construction is from press-formed 3mm instructions. The TR-4050 advantages
The complete plug-and-play Cascadia cold-rolled steel. The stubby design include a 6.16:1 First gear and a 0.76:1
Vehicle Specific Solar System can report- increases clearance while saving weight. Fifth gear overdrive. SST can also mate
edly be installed in under 11⁄2 hours. It Other features include integrated D-rings the TR-4050 to popular non-Jeep engines,
continuously charges the vehicle’s bat- and lift points, removable mesh panels including the Cummins 4BT and 6BT; the
tery during daylight and can help power for customization, and auxiliary backup Ford 5.0L and Windsor small-block and
auxiliary accessories such as refrigera- light cutouts. Finish is dual-stage black Coyote; the Chevy small-block, big-block,
tors, inverters, and more. The system can powdercoat. INFORMATION: Smittybilt, and LS; and the Mopar small-blocks and
also provide jumpstarting juice. INFOR- 888.717.5797, smittybilt.com. Gen III Hemis. A41X automatic kits are also
MATION: Cascadia 4x4, 604.562.8809, available. INFORMATION: Silver Sport Trans-
cascadia4x4.com. missions, 888.609.0091, shiftsst.com.
BY 4WOR staff
EDITOR@4WOR.COM
PRO COMP
SUPER DUTY
COILOVERS
For 2005-2019
F-250 and F-350
trucks, Pro Comp now
offers an adjustable
front coilover kit. The
kit provides between
3 and 4 inches of lift.
The kit uses nitrogen-
charged 2.5-bodied
monotube shocks
with remote reser-
voirs. Mounting hard-
CPT SCOUT POWER STEERING CONVERSION KIT ware and bumpstop
Crawler Proven Technology (CPT) offers a complete power-steering conversion kit for 1969- extensions are includ-
1971 Scout 800A and 800B 4x4s with the IH 304 V-8. Components include a new steering box, ed. INFORMATION: Pro
pump, pump bracket, pulleys, belts, hoses, hardware, and instructions. Installation involves Comp, 800.776.0767,
cutting and welding. INFORMATION: IH Parts America, 530.274.1795, ihpartsamerica.com. procompusa.com.
AEROMOTIVE SILVERADO/SIERRA CHANNELLOCK

PERFORMANCE FUEL PUMPS SPEEDGRIP PLIERS
Aeromotive now offers a line of fuel A new line of the
pumps for performance-modified 1999- famous tongue-and-
2018 gas-powered Chevy/GMC groove pliers has a fast-
trucks. They are designed as adjust feature. The adjust-
complete in-tank upgrade ment button locks the
kits and come with the pliers into the select-
pump and baffle/basket. ed channel, pre-
Single-, dual-, and triple- venting slippage.
pump systems are available Manufacturing
to support power outputs of uses robotic laser
800 to 1,300 hp. Available flow rates are heat-treating to
published as 340-450 lph. INFORMATION: strengthen the
Aeromotive, 913.647.7300, aeromotiveinc.com. patent-pending
crosshatch teeth
RUFFSTUFF FORD F-150/RAPTOR and no-slip com-
9.75-INCH DIFFERENTIAL COVER fort grips to ease
RuffStuff set out to design the tough- hand fatigue. The
est-available F-150/Raptor diff cover for SpeedGrip pliers
applications dating back to 1997. Each are offered in a
is handbuilt from 3⁄8 -inch plate, welded three-plier combo
inside and out, and machined perfectly pack as well as in
flat for leak-free sealing. The fill plug has three individual
a 1-inch inside diameter for easier filling sizes: 8, 10, and 12
and level checking. Options include a inches. The pliers
Lube Locker gasket and 12-point 5⁄16-inch are made in the USA
bolts with washers. These USA-made diff and also feature a
covers are backed by a lifetime warranty. limited lifetime war-
INFORMATION: RuffStuff Specialties, ranty. INFORMATION: Channellock,
916.600.1945, ruffstuffspecialties.com. 800.724.3018, channellock.com.
accessories all interchange, including the ears clear the knuckle, then most likely the
water pump itself. In other words, putting splines have twisted in the side gear of the
a serpentine system on an earlier engine locker, and this is preventing the shaft from
is a bolt-on affair and vice versa. Standard coming out. If you had an open differential,
and reverse-rotation pumps look identical the solution is to remove the cross shaft in
externally, with the only difference being the differential, pull down the other side,
the design of the veins in the water pump and use a long bar to beat the broken axle-
itself. This small but important change is shaft out. But since yours has an aftermar-
what makes the water pumps specific to the ket locker, there’s no cross shaft to remove
type of accessory drive system being used. and you’ll need to get a little more creative.
If a reverse-rotation pump is installed with You have a couple of different options
standard V-drive accessories, the pump will for getting the shaft out, one of which you
cavitate because it’s running backwards already mentioned. You can weld a nut to
and does a very poor job of circulating the center of the axleshaft and use a slide
OVERHEATING TBI 350 water through the cooling system. hammer to drive the axle out. Another
Q I put a Chevy TBI 350 in my buggy last We would double-check the part number option is to fashion a press using some all-
year. I don’t know what it came out of, for the water pump you installed on the thread and some steel that straddles the
but I put all new accessories on it, includ- engine if you still have it. If you ordered a hole in the knuckle. Find a chunk of steel
ing a water pump. I also installed a new pump for a TBI engine but are running V-belts, that’s longer than the hole in the knuckle
thermostat, a new four-core aluminum more than likely you have the wrong water (the thicker the better), and drill a hole in
radiator, a new fan shroud, a 16-inch Spal pump on the engine. What you need is a it. Position the steel on the knuckle, slide
fan, and all new accessories and belts. It pump for a 1986 or earlier application. Fortu- the all-thread through the hole and thread
overheats constantly and even runs hot nately, the fix is inexpensive as both types of it into the nut welded on the axle, and then
at idle. Whether it’s under load or idling, Chevy water pumps are plentiful and cheap. use another nut against the piece of steel
the temperature just keeps climbing. If I One other thing worth mentioning is to pull the axleshaft out. Once out, you’ll
leave the cap off and run it up to operating whether or not you’re running a heater. want to go ahead and pull the locker out to
temperature, when the thermostat opens We’ve noticed that it can be very difficult to inspect the side gears. It’s not uncommon
it gushes out coolant out of the radiator. I purge all the air out of a small-block’s cool- for the splines to be messed up, especially
don’t think it’s an air pocket, as it has been ing system when the heater hose ports are if the shaft didn’t just twist but actually
burped, but coolant keeps gushing out. I capped off or eliminated. The circulation of broke inside the side gear.
thought it was a head gasket, so I did that coolant through a heater core was part of
three weeks ago and still have the same the engine’s overall cooling system design,
issue. Temps at idle are 210 degrees or and capping off the heater hose ports cre-
more and slowly keep climbing, and temps ates pockets for air to get trapped. If you’re
while driving are 240-plus. Any ideas? not running a heater, we would recommend
ROB R. connecting the heater hose ports together
Via nuts@4wor.com in a loop rather than just capping them off.
You’ll find it makes purging the cooling sys-
A Overheating issues can be frustrating, tem a lot easier.

but we’d be willing to bet solving yours
is going to be pretty easy. You mentioned BUSTED DANA 30
that you installed new belts, rather than a
single new belt. Multiple belts indicate that Q I have a Dana 30 in my TJ with a Griz-
zly locker. I broke the long side axle- LONG-ARM TTB
Q
you’re running a traditional V-belt drive shaft and now it won’t come out. I welded I have a 1994 Bronco with a TTB
system as opposed to a single serpentine an eyelet to the shaft and tried using a frontend. I acquired a set of extended
belt. This, plus all of the symptoms you winch to pull it out, and it’s just trying to radius arms for free. I already have a
describe, points to having the wrong water pull the Jeep off the jackstands. I tried 6-inch lift and all the drop brackets, so I
pump on the engine hitting and pulling, to no avail. Now I’m would just be adding the longer arms. Is it
When Chevrolet went to throttle-body thinking of making a slide hammer out of worth the work?
injection in 1987 it switched to a serpentine some pieces I have lying around here. Any EVAN M.
accessory drive system at the same time. other ideas? Via nuts@4wor.com
This is significant because the routing of BROOKS H.
A
the serpentine belt required the water Via nuts@4wor.com Absolutely. The stock Ford TTB radius
pump to spin in the opposite direction of arms are made of thin stamped steel
engine rotation. The traditional V-belt drive
systems used prior to 1987 had a standard A We’re assuming the ears on the broken
axleshaft haven’t spread and are pre-
venting the axleshaft from sliding through
and are comically short. They work fine
with stock suspension, but once lifted the
rotation pump, meaning that the water arms seriously inhibit suspension travel.
pump spins in the same direction as the the hole in the knuckle. We’ve had to beat, The longer radius arms improve suspension
engine. The front of TBI 350s and 1986-and- grind, and even cut off the ears of an axle- travel, reduce bushing wear, and just plain
earlier engines are physically identical, so shaft in order to remove it in the past. If the look better.
BY Trenton McGee
NUTS@4WOR.COM
The one question is which combination of environments because the mechanical

frame brackets you are supposed to use with lock keeps the wire securely attached, but
the longer arms. Some aftermarket radius arm they don’t offer the same conductivity as a
designs involve relocating the stock radius soldered connection. Soldered connections
arm mount on the frame, some have their own offer superior conductivity but are more
frame brackets, and some use a combina- likely to work-harden and break. With either
tion of the factory mount with a shorter drop connection it’s a good idea to have a weath-
bracket. If possible, see if you can get the erproof cover over the connection to keep
mounts from the same source that’s giving out moisture and prevent corrosion.
you the radius arms, or at least look at the While we haven’t tried them ourselves, we
frame and see what mounts were used. If not, are still a little skeptical. The makers have
try and identify the manufacturer of the arms clearly altered the chemical properties of
and see if you can find a copy of the installa- the solder inside to melt at a lower tempera-
tion instructions. These instructions should ture than normal solder. Normal solder won’t
tell you what mounting configuration was melt at the temperature most normal heat
used and the measurements needed to relo- guns are capable of generating. We don’t
cate the brackets on the frame. available in 3-, 31⁄2 -, 4-, 5-, and 6-inch diam- have an electrical engineering degree, but a
Don’t forget to install some new bushings eters. The tube has a variety of straight and reasonable conclusion would be that solder
with your new-to-you arms, and you can angled sections that you can cut and piece that melts at a lower temperature won’t
count on needing an alignment once the together using silicone clamps to route the be as strong. It also seems like it would be
arms are installed. intake pretty much anywhere. The UBI tube tricky to apply just the right amount of heat
is textured plastic, but it’s pretty thick and to melt the solder without scorching the
SNORKEL, HOLD THE DORKEL UV-stable, so it looks much better than black shrink tubing, and it would be difficult to
Q I have two trucks that I wheel, a 1980 PVC from the hardware store. Tech Editor inspect the finished connection to ensure
K20 and a 2006 Chevy 1500HD. I’m Verne Simons built a snorkel using UBI com- the solder fully melted and the shrink tubing
looking for a snorkel that I can adapt to ponents, and it looks pretty professional in uniformly sealed. Still, it’s hard to speak with
either vehicle, as I can’t find anyone that our opinion. The filter hat was something he any authority without some hands-on expe-
makes a snorkel for either vehicle. I live in made, but the components used are straight rience, so we’d be curious what anyone else
northern Canada and we have lots of deep from the Airaid UBI catalog. The company has to say about them, either good or bad.
waterholes, so I need something better offers couplers and reducers, assorted hard- Though it’s a little more labor intensive, we
than the factory intake. I find most home- ware, and even a carburetor hat that should prefer to use uninsulated crimp connector
made snorkels look horrible and would like work perfectly on your K20. You’ll likely need and dual-wall heat shrink tubing. Once the
something with better fit and finish. I know to modify the stock air box on the 1500HD, connector is crimped, we solder it and then
it won’t be perfect, but I’m hoping you can but connecting the UBI tube to the box slide the heat shrink in place. The heat shrink
point me in the direction of something that should be pretty easy. Lastly, while it’s not we use is lined with adhesive, which melts as
looks clean. Thank you for the help, and something that Airaid offers, we have occa- the tubing shrinks and adheres to the wire
hopefully someday I can join the Ultimate sionally seen the snorkel-shaped tips online. insulation, forming a weatherproof seal.
Adventure with you guys and really test out
my equipment! SOLDERED CRIMP CONNECTORS
DANIEL W.
Via nuts@4wor.com Q I found some electrical connectors
online that looked like they would
work pretty well for 4x4 applications. They
A Unless you own something like a Jeep

Wrangler JK or JL, finding an off-the-
shelf snorkel for your vehicle is next to
are an insulated crimp connector with
solder built in. Once you crimp the wires
together, you use a heat gun on the con-
impossible. And we, like you, have seen some nector that melts the solder and shrinks
homemade snorkel setups that are anything the insulation at the same time. It seems
but visually appealing. While it’s possible to like they would be about as easy as regular SUBMISSION INFORMATION
make a working snorkel using bits from the butt connectors while offering a better Confused? Email your questions to the
plumbing and garden departments at your connection. Have you used them, and if so, address below with “Nuts, I’m confused”
local hardware store, it’s just about impos- what do you think? as the subject. Include a picture, if appli-
sible to make that stuff look good. GARY V. cable, no smaller than 1600 x 1200 pixels
Fortunately, you’re not completely on Via nuts@4wor.com (or two megapixels) as a TIFF, EPS, or
your own when it comes to making your own maximum-quality JPEG. We also read the
A
forums on (4wheeloffroad.com).
snorkel. We’ve had excellent luck making We’ve seen the connectors you’re talk-
WRITE TO: Nuts & Bolts, 4-Wheel & Off-
our own intake systems and even snorkels ing about. At a glance they seem to offer Road, 831 S. Douglas St., El Segundo,
using the U-Build-It product line from Airaid the best of both worlds: the mechanical CA 90245
(airaid.com). Though intended for under- clamp of a crimp connector and the superior FAX TO: 818.566.8501
hood applications, the Airaid UBI system connection of a soldered connection. Crimp EMAIL TO: nuts@4wor.com
consists of a roughly U-shaped tube that is connections are preferable in high-vibration
BY Harry Wagner
EDITOR@4WOR.COM
LOOSE LEAF ISN’T JUST FOR PAPER the Cherokee all the way from Phoenix to
S teven Messer’s 1979 Jeep Cherokee

is super-built, with an LS3 engine,
an eight-speed automatic transmission,
Alaska and back for Ultimate Adventure
2019. On the last day of the trip though
they broke a center pin on the front, driver-
and 1-ton axles capped with 42-inch tall side leaf spring. This is the pin that holds
tires. Perhaps surprisingly, it still uses the the spring pack together and locates the
original leaf spring suspension. All of that axle. A spare center pin is inexpensive and
power and big tires mean that a crazy-flex- doesn’t take up much room, but Steven
ible suspension isn’t necessary on the trail, didn’t have one. Fortunately Rick Péwé had
and the leaf spring suspension is stable a center pin in his “junk drawer,” and with
enough to do freeway speeds all day long. the help of UA crony Keith Bailey, the Mess-
In fact, Steven and his wife, Kathy, drove ers were back on the trail in no time.
MARCH 2020 VOLUME 43, NUMBER 3

SUBMISSION INFORMATION 4-WHEEL & OFF-ROAD (ISSN 0162-3214). Copyright 2019 by TEN: Publishing Media, LLC. All rights reserved.
Send us your wheeling foul-ups! Letters Published monthly by TEN: Publishing Media, LLC, 275 Madison Avenue, 14th Floor, New York, NY 10016.
must be signed by the vehicle’s owner. Due Periodicals postage paid at New York, NY, and additional mailing offices. Printed in the USA. Single copy
to the large volume of mail we receive, we price is $6.99. Subscription rates: U.S. and U.S. Possessions, one year $18; Canada, one year $30; all
regret that not all submissions can be used other countries, one year $42 (includes surface mail postage). Payment in advance. U.S. funds only.
POSTMASTER: Send all UAA to CFS. (See DMM 707.4.12.5); NON-POSTAL AND MILITARY FACILITIES: Send
and none will be returned. Digital photos
address corrections to 4-Wheel & Off-Road, P.O. Box 420235, Palm Coast, FL 32142-0235.
must measure at least 1,600 by 1,200 pix-
els (or two megapixels) and be saved as a GET EVEN MORE 4-WHEEL & OFF-ROAD ON YOUR COMPUTER OR SMART PHONE AT THESE SITES
TIFF, an EPS, or a maximum-quality JPEG file.
WRITE TO: Whoops!, 4-Wheel & Off-Road,
831 S. Douglas St., El Segundo, CA 90245
FAX TO: 818.566.8501
EMAIL TO: editor@4wor.com facebook.com/ instagram.com/ twitter.com/ youtube.com/user/ bit.ly/2FMRfHN
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MARCH 2020 VOL. 43, NO.

DEPARTMENTS ON THE COVER: Well, this is awkward. Our

VISITING REAGAN’S RANCHO DEL CIELO

Single Wheel &

UNLIMITED OWNER: Jason Miller, East Berlin, PA TIRES &

> VEHICLE (year, make, model)

geico.com | 1-800-442-9253 | Local Office

2021 COLORADO GOES DESERT RACING

• RUMORS ARE CIRCULATING at bollingermotors.com/reserve.

…AND SO DOES SILVERADO

4WHEELOFFROAD.COM 4-WHEEL & OFF-ROAD MARCH 2020 9

• SEMA REPORTS THAT FOR

4WHEELOFFROAD.COM 4-WHEEL & OFF-ROAD MARCH 2020 11

12 MARCH 2020 4-WHEEL & OFF-ROAD 4WHEELOFFROAD.COM

DANA IH PARTS AMERICA PREMIER POWER WELDER VOODOO OFFROAD

FAB FOURS OFFROAD DESIGN SKYJACKER SUSPENSIONS

4WHEELOFFROAD.COM 4-WHEEL & OFF-ROAD MARCH 2020 13

BY Harry Wagner EDITOR@4WOR.COM PHOTOGRAPHY HARRY WAGNER AND COURTESY OF SEMA

14 MARCH 2020 4-WHEEL & OFF-ROAD 4WHEELOFFROAD.COM

NUCAP® NRS® hook

4WHEELOFFROAD.COM 4-WHEEL & OFF-ROAD MARCH 2020 17

ished, or black ﬁnish options. ProCharger SMARTKITCHEN

22 MARCH 2020 4-WHEEL & OFF-ROAD 4WHEELOFFROAD.COM

2 We started by accessing a drain point where

3 We used a barbed ﬁtting (Hayden Automo-

5 We started the warmed-up Jeep and let the

6 Next, we unbolted and dropped the transmis-

9 We thoroughly cleaned the stamped steel

10 An O-ring seals the ﬁlter outlet to the valve

11 To reseal the transmission pan we used

12 At this point, we added 4 quarts of

ADD QUICK & EASY BODY

1 We call this 1984 Jeep CJ-7 our “weenie

2 We purchased the Warrior rear corners

3 Of course, everything needs to be removed

corner armor. In our case, that included the

4 On the passenger side, the ﬁller neck needs

8 We purposely drilled the spare tire car-

9 The procedure for the passenger side was

10 Not many people are making new prod-

9 11 We used a ﬂoor jack to hold the rock

DASH REHASH FIXING AN AGED TRUCK DASH

30 MARCH 2020 4-WHEEL & OFF-ROAD 4WHEELOFFROAD.COM

1 We’re pretty sure our old Dodge has spent

2 This is our pièce de résistance of the dash

3 Then you have to make sure the dash cover is

CHEVY VORTEC 454

2 With a truck that’s been parked as long as

the basics. First, we had to see if the engine

7 With the tank dropped, we installed a Delphi

8 We surmised that the fuel injectors were

9 We found a local shop, Rods Carburetor in

Stream all-new episodes now, only on

EASY JEEP JK BIGGER

WRANGLER FOR YOUR

1 2 The kit comes with detailed instructions, and

3 The Dynatrac instructions clearly explain

4 The Dynatrac ProGrip Brake System ﬁr JK

3 Randy Slawson debuted his new “bash

4 This trail gets your attention right off the

6 There isn’t much Samurai left on Robbie

7 Kaitlyn Tydeman’s Samurai buggy has

8 Mark Schultz taught us a trick about keep-