Achieving New Heights: Phase One of Our Budget 1999 Jeep Wrangler TJ Project

For longtime Jeep enthusiasts, this report, the first in a series of articles about modifying a 1999 Jeep Wrangler Sahara, might rehash upgrades you've been familiar with for a long time, by way of reading past articles and/or executing some of the projects on "TJ" Wranglers yourself.

Arguably one of the 10 best Jeeps of all time, 1997 to 2006 Jeep Wranglers are now experiencing a resurgence. Enthusiasts are avidly shopping for and snapping up the OG rigs, preferably Rubicon models, and the more stock they are, the better. We've always been impressed with Arden Ethridge's 2003 TJ, which, while built on a tight budget, includes almost all of the upgrades the platform supports, and allows Arden to rockcrawl, trail-hop, and confidently do all the off-road things his heart desires.

Our build candidate is a super-clean, low-mile 1999 Jeep Wrangler Sahara that has never experienced any true off-road action. Previously owned by a senior couple, the Jeep served as a "daily driver" that was towed by their motorhome and used for shuttling around various vacation destinations. Chuck and Yolanda Jackson are the TJ's new owners, and although they have "motorhome-shuttle" plans for their Jeep, they also plan to hit the sand with it and explore nature more than the original owners did.

Related: Budget-Friendly DIY Off-Road Light Upgrade for 1997-2006 Jeep Wranglers

With that being the proposed strategy, a more hardcore Jeep "look" is desired, first and foremost, as well as functional changes that will make the rig capable of running through the dunes and anywhere else the Jacksons care to take it. Lifting the chassis and swapping the wheels and tires are the first steps. Robby Toth of Scott's Tires and Wheels in Rancho Cucamonga, California, is the expert who assisted us with the change, which includes Skyjackjer's 2.5-to-3-inch suspension lift featuring all-new ADX 2.0 Adventure Series remote-reservoir shocks, and Mickey Thompson 15x8 Classic Baja Lock wheels with new 33x10.50R15 Baja Legend MTZ tires. Parts that Robby is installing are all available from Summit Racing, as are lights and other accessories we'll highlight in future installments.

Sahara,NotRubicon

Our build is based on this 1999 Jeep Wrangler Sahara, not the more popular Rubicon model that is factory-prepared for off-roading. Although this model is a perfect unit to upgrade for extreme off-road use, we're setting it up for sand dunes and light woods fun with modifications that won't compromise its street drivability. As part of the TJ's makeover, Chuck installed a new soft top and fender flares to support the new, wider Mickey Thompson Baja Legend MTZ tires.

The Jeep sits on stock 15-inch aluminum wheels with 225/75R15 radial tires. Looking closely at this photo, you can see the front and rear tires have mismatched tread.

Before disassembling the Wrangler's suspension, Robby measures stock ride height. The measurement is 36 inches from shop floor to fender.

After raising the Jeep and securing it on jackstands, the stock springs, shocks, and their associated hardware are removed.

A multilink, coil-spring suspension system returned to Wrangler in 1997 (replacing a front-and-rear leaf-spring setup that had been used for many years). This is one of the TJ platform's major highlights, which improved on-road handling and drivability as well as off-road control.

When removing original parts on older vehicles it's always a good idea to use liberal amounts of spray lubricant to free up stubborn fasteners.

New Shoes

In addition to a suspension lift, wheels and tires are the all-important final touch for stage one of any Jeep Wrangler appearance makeover. For the Jacksons' TJ, a complete Mickey Thompson package is being installed. Taller, wider 33x10.50R15 Baja Legend MTZ tires are more than appropriate for this build. The self-cleaning, three-ply, mud-terrain radials feature high-void tread lugs with variable-angle siping for aggressive traction in tough mud, and loose terrain like the desert sand this Jeep will potentially play in. Despite the aggressive off-road profile, the Baja Legend MTZ's advanced radial construction should give it good highway manners too.

The Classic Baja Lock wheels are 15x8, and with the faux beadlock design, they definitely have the more hardcore off-road look we're striving for.

Elevation

Skyjacker offers new reservoir shocks and coil springs for 1997-2006 Jeep Wrangler as an all-inclusive set that can lift the vehicle between 2.5 and 3 inches.

Front and rear coil springs are taller, direct-replacement pieces that don't require additional components other than bump-stop spacers and 10 x 70mm fasteners that are included (and installed in the stock cups).

We decided to complement the lift with Skyjacker's new ADX 2.0 remote-reservoir shocks. The lightweight, high-volume aluminum dampers are designed to absorb extreme off-road impacts and dissipate heat that can cause shock fade. They also provide a smooth, stable ride in pavement conditions, and they look really good.

Robby installs the Skyjacker coil springs and ADX 2.0 remote-reservoir shocks in the 1999 Jeep Wrangler Sahara's front end. There are no tricks or special requirements for putting these pieces in place.

Here's a look at one completed side of the new front springs-and-shocks upgrade. Skyjacker provides clamp-style brackets for securing reservoirs to the shock bodies. The only thing to be mindful of is ensuring the shock-to-reservoir braided lines aren't kinked, as that would impede fluid flow.

The rear suspension requires more extensive disassembly for the parts exchange than the front end does. Control arms are disconnected and the rear axle is lowered to facilitate extracting and installing coil springs. The lift requires relocating the rear track bar as well, which is done using an extension bracket that fits over the factory track-bar mount.

With the track bar relocated and axle resecured, Robby installs the rear Skyjacker ADX 2.0 remote-reservoir shocks. Thankfully, the shocks aren't difficult to compress, so bolting them in at the axle isn't a nightmare. Cam bolts are included in the suspension package, and used as necessary to adjust rear pinion angle and eliminate driveline vibrations. Wheel alignment on a newly lifted 1999 Jeep Wrangler Sahara is for toe-in adjustment, but more so centering the steering wheel. Robby does this by loosening the clamps on the drag link and rotating the short adjustment link until the wheel is centered.

The installed Skyjacker lift-springs-and-shocks combination looks great.

This is our project 1999 Jeep Wrangler TJ before the upgrades.

And here's the Sahara's profile after adding Skyjacker's 2.5-to-3-inch suspension lift, Mickey Thompson Classic Baja Lock, and Baja Legend MTZ wheels and tires. Collectively, the modifications raised the Jeep a total of four inches (40 inches from floor to fender).

The Baja Legend MTZ's tread is aggressive and designed to primarily take on dirt, mud, and other off-road conditions. On pavement, however, "tire noise" can be heard inside the Jeep, and we detected light vibration through the steering wheel. Despite the big lugs, the tires don't create any on-road steering or handling issues. The shocks also do a great job of providing a smooth ride and making the TJ easy to maneuver with the higher profile and big tires.

Phase one completed. In this photo, looking beyond how awesome the newly lifted TJ's stance is, you can see the old-school lights, faded bumper, and small, dated side steps that we will address in the next installment of our 1999 Jeep Wrangler Sahara build. Hella's stealth Black Magic LED lighting is on deck, along with other upgrades that we found in the Summit Racing catalog, so stay tuned for future reports.

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