Well, I'm sitting over here in Afghanistan trying to figure out what all to do to my 04 TJ when I get back home to Salt Lake City.

Currently its pretty close to stock, I have a 2in lift and 31" BFG mud terrains. I have the factory limited slip in the rear, and an auto locker in the front. And I have some rock rails, and a warn rear bumper

I've taken my Jeep down to Moab and done some of the easy/moderate trails and I've wheeled around the Wasatch front in UT, and I'm ready for the next level.

My plan is to make it capable off road while keeping it street legal. I plan on buying a car when I get back to the states, and using my Jeep as a second vehichle.  I will however drive the jeep daily during the summer.

Heres what I'm thinking about, keep in mind this is the early stages of planning and I'm open to suggestions.

5.5" lift (no idea what brand yet)
35" BFG mud Terrains
Not sure if I should upgrade to Dana 44s or if chrome molly axle shafts would be sufficient in the stock Dana 30 and 35.
And for traction I'm thinking I would like to try some OX lockers.
geared to 4.56

after that I'll start in on the accessories

tire carrier for my warn bumber.
warn front bumper and a winch.
wider fender flares
rhino line my floor

Then lastly I want to add more power, I realize more power isnt necissary for driving off-road, but it'll sure make the drive to and from moab a lot nicer.

I was reading about all the V-8 swaps people do, and was thinking about a 5.7L Hemi,  But as I think about it more, I'm thinking I might like to have something like a 4.0L bored to 4.6L.  And if that still hasnt satisfied my need to go fast on the highway (the speed limit on the highway to Moab is 75mph), its possible I then add a supercharger.

So thats what I'm thinking about, I realize I'm probably forgetting a lot of small things that will get done along the way.  And also I plan on paying for most of the work to be done for me, possible by the guys at Sky's Extreme. So I'm sure they'll also be happy to give me input on my Jeep.

So what do you think?  Anything big I'm overlooking?  And particular brand parts, such as lifts and what not you think I ought to install?

At the moment I have nothing but time to sit and think about my Jeep, so any input positive or negative is welcome.  

it sux that there are 70+ views and no response....

at any rate. while my experience is not exactly in the TJ, let me suggest that whatever suspension you choose, if you are shooting for 5-6" of lift, get a long arm system. It will be worth it. it's alot of cash up front, but the driveability and potential for twisty suspension is worth it.

for gearing, 4.56 would be the minimal. you may CONSIDER 4.88s, and yes, aftermarket shafts are recommended. (personally) I have been running a ZJ on 33s with 4.56 gears and OEM shafts for about 4 years. I finally busted a ujoint in the D30 in september on a trip to Moab.... right after I installed an Aussie Locker. i knew it would break, so no surprise.

also, with the lift and tire increase, you may consider a beefy steering upgrade. what you get is your choice. between beef and other mods required (teraflex), it is up to you. I chose the Teraflex HSKT on my ZJ, and even though I had to mod other things, I am VERY happy with it. cured some bad habits the ZJ had.

just a suggestion. dont worry much about the 4.0 power. I have a 4.0 in my ZJ. with 4.56 and 33's, it still hauls pretty good. I do have a Banks Torque Tube header and a "custom" airbox running into a '03 TJ intake... which you already have. the only "bad" thing being the head on your engine. I'd just do some power upgrades... intake, exhaust and a new computer or chip. There are several positive things on the Edge system.. computer, throttle body and intake.

being as you are in Afghanistan, I will assume you are with our armed forces.... so stay safe and keep your head down!  

b1pig mirrors my sentiments.  Especially about staying safe and coming home in one piece.  Thanks, man.

For starters, 5.5-inches is a tall kit, so yes, a long arm is pretty much mandatory.  It sounds like you're taking this Jeep to the extreme side of things, so you may consider a 4-inch long arm suspension instead and running some tube fenders up front and cutting out the tub in the rear for the added tire clearance.  This works well for 35s and will result in a lot more stability at angles.  The lower lift will also help alleviate driveshaft buzzing from the front driveshaft, which can sometimes be a problem at lift heights of 5.5-inches or bigger.

As for the axles, when I was crunching numbers for "Project Steal-J" it was hard to ignore the value of the D44 assemblies from Drivetrain Warehouse.  You reuse your knuckles and brakes on the front and your rear brakes on the back, but otherwise they're spankin new and the price comes suprisingly close to what you'd be into setting up the factory axles with similar components.  Mine were outfitted with ARBs, 30-spline alloy shafts in the front, and 33-spline alloys shafts in the rear.  If I remember correctly the price was just over $5000 for both and that includes an ARB mini compressor.  Set up like they are my axles should easily survive with 37s and a 4.0L or 35s and a healthy V8.  As for gears, I'd consider 4.88s since you're in the mountains of Utah.  I've got 4.56s with 32s here in SoCal and it's just about right for me, but I always err on the high side of the tach.

He's right about the power mods as well.  I'd keep that 4.0L in there until it's got at least 150K on it. For reliability and durability you really can't beat the factory 4.0L.  Add an air intake, 62mm throttle body, header, and after cat exhaust and you'll have an extra 15hp at the rear tires.  Then, if down the road you do get the itch for a supercharger you've got the components in place to support it.  

Good advice from two knowledgeable people right there!  

hey i hear you im doing the same from iraq with my 06. i started with a fabtech 6in, and 33's because i was worried about my dana axles. i was going to order the awesome 30/35 kit from 4wheelparts.com, but with the extra weight of bumpers and the possibilty of pulling a bass boat when not four wheeling. I elected to go with G2 dana 44's from drivetrain warehouse with ARB lockers, and alloy axles, and 4.56 gears for around 5 g's in addition im going with a kenne bell supercharger for 3800.00. Im also looking at a banks header, catback, but im trying to avoid having my daily driver down for days at a time, thing about the lift and avoid the mistake i already made of having to buy 2 new driveshafts due to; first the lift required a new rear drive shaft with a fixed yoke eliminator for the transfer case and second i need  new shorted axles to compensate for the longer pinions on the 44 danas. I'm no expert just trying to pass on what i have learned.