I am currently in Iraq and will be returning home soon. I purchased an 1998 Wrangler Sahara Edition, 6 cylinder, 5 speed. Has both hard and soft top..will probably use hard top most of the time. Here is what I plan on doing to it. I would like opinions from all if this is along the right lines.

I want to be able to use 32" tires and a possible upgrade to 33's later. The Jeep itself will be exposed to a variety of duties but mainly freeway speeds of 75 to 80 MPH.

I like the 2.5" Rancho lift kit. In addition to this I will probably purchase upper adjustable control arms to regain as much wheelbase as possible. I am thinking about the Rancho RSX type shocks to go with this as well. If I need to add a 1" spacer I can do that too.I think that will make plenty of room for the 32" tires on some type of cragar or other type 15x8 rim. I want to also use the antirock swaybar kit for the front. If I run it on it's stiffest setting, will I have any issues on the highway?

In the front D30, I am going to buy brand new axles and equip it with a trutrac...might go with Auburn Gear ECTED. Will regear to 3.73 or 4.10 gears. Really leaning toward the 3.73's.  In the rear D35, I will regear it as well, replace with new 30 spline axle, and thinking about going with The Auburn Gear ECTED. I like the idea of the limited slip to locker.

That is pretty much the big stuff. I also plan on getting the small things done like new battery and engine tune-up and so on. I also have to replace the steering box and pump thanks to my wife....(long Story short...she got it stuck and broke alot of stuff....including the front axle)I can do most of the work myself. I will have to farm out the axles as I am not familiar on gear changes. Total cost is about $5000 without labor on the axles.

So my question to all of you out there.... Is there any part of this configuration that is not right or could be made better while keeping it right around the $5000 - $6000 budget. Any input is always greatly appreciated. I will check back as often as as I can...but if I don't respond right away...don't give up on me. We are busy at times. I will do my best. Thanks!!  

I would get at least 4.10 gears.  My '02 Sahara has 3.73's and I'm going to change to 4.10's.  It's what everyone on here recommended me to do.  With 33" tires 4.56 would be even better.  

with the 5spd even the idea of 33's should get 4.56's in there even for the 32's
Ideal gearing is 4.88' for 33's  

Would not recomend the ECTED lockers.

If you want electric lockers go with Eaton E-lockers.

The ECTED's have had problems and poor customer service. Even when the ECTED was defective, Auburn would not pay for the re-install.

Also, it's not worth putting money into a selectable locker and alloy shafts for a Dana 35 and 33" tires. The Dana 35 has a dismal track record. It can barley survive as an unlocked diff and any diff needs to be much stronger to run locked.

I've never seen a TJ Sahara that had a Dana 35 rear though. They all have Dana 44's. So, double check that.  

I have not seen this vehicle yet..It may have a D44 in the rear. I can't check until I get home. I just "assumed" it was a D35 for pricing purposes. So the ECTED is out, and the eaton is in. What about a Truetrac in the front axle? As for gearing..if I 4.10's will work, that is what I will use. I really don't want to go to tall simply because of the RPM's. The first thing this jeep has to do is make a voyage from Ohio to Kansas roughly 900 miles, most of them on I-70 at speeds of 80MPH or more.

So it looks mainly like all the issues are in the axles and gearing. Not a problem. I will make those changes. Just need some info on that truetrac.

Is the 2.5" Rancho a good lift? if not, I was thinking about going with the Rubicon Express 3.5" superflex lift. It's a little more than I need, but does allow for future adjustments.

Thanks for all the info so far. Keep it coming. I will check back later.  

mud runs the 2.5 rancho lift and clears 34s. he even has had 35s on it one time, your 32s will look little on it. i would go with at least a 33 to start with if you are running the the 2.5 rancho  

Don't hear too much about the TrueTrac. Mostly because it's pretty expensive. For not much more you can get a selectable locker.

"Lunchbox Locker" are lockers that install inside an open carrier in place of the spider gears. They are a do it your self install. The LockRight is a lunchbox locker. The Truetrac is a whole differential replacement, which usually requires professional installation.

The most common lunchbox lockers that you see a lot of, are the LockRight installed in the rear and an AusieLocker installed in the front.

As far as a lift is concerned. Read some of the other threads going on about suspension recommendations.

3 inches and over requires a lot more money than 2.5 or less.

Stick with OME springs and shocks. They're the best.

Super flex control arms won't get you anything. Save your money.

Shocks are the most important feature of your suspension, and springs are second. That's what you feel.

Lift springs are designed to lift and how they ride is not a concern. And the shocks are even worse. Steer clear of the "lift" springs and shocks.  

ftgiles:
Would not recomend the ECTED lockers.

If you want electric lockers go with Eaton E-lockers.

The ECTED's have had problems and poor customer service. Even when the ECTED was defective, Auburn would not pay for the re-install.

Also, it's not worth putting money into a selectable locker and alloy shafts for a Dana 35 and 33" tires. The Dana 35 has a dismal track record. It can barley survive as an unlocked diff and any diff needs to be much stronger to run locked.

I've never seen a TJ Sahara that had a Dana 35 rear though. They all have Dana 44's. So, double check that.

Some Sahara's have D35's depends upon the package you get from dealer. My dad has 2001 Sahara with D35. Most have the D44.  

ftgiles:
Would not recomend the ECTED lockers.

If you want electric lockers go with Eaton E-lockers.

The ECTED's have had problems and poor customer service. Even when the ECTED was defective, Auburn would not pay for the re-install.

Also, it's not worth putting money into a selectable locker and alloy shafts for a Dana 35 and 33" tires. The Dana 35 has a dismal track record. It can barley survive as an unlocked diff and any diff needs to be much stronger to run locked.

I've never seen a TJ Sahara that had a Dana 35 rear though. They all have Dana 44's. So, double check that.

Jungleboy4:
Some Sahara's have D35's depends upon the package you get from dealer. My dad has 2001 Sahara with D35. Most have the D44.

I'd like to see that! I've never seen a single sahara with a d35 myself either...  

I had never seen one with a 35 in it either until my dad brought home that pile. He bought it from a freind of a freind and so on and so on. Maybe it's a swap, but it's definitly a 35.  

dang...  

I'm going to see if my dad can send me a picture of it, and I'll post it. is it possiable it came from the factory, or is it a swap? Go figure, right? I mean who'd swap out a Dana 44 for a 35? Doesn't make alot of sense.  

Well when I bought my Sahara I was doing some research and Chrysler spec sheet said that it had a d 35 rear.  But it aint no 35.  It also said it came with 3.07 gears but it aint that either.  So who knows what they did.  

Sounds like a mix up between marketing and production folk.  

The D35 is standard for the Sahara. But it was sometimes a free option (marketing special) with the Sahara and cost like $100 when it wasn't free. So, that was always a no brainer option to include. But starting in 2000 it was included with the Sahara 30" tire and wheel package.

Anyway, before I bought my TJ, I looked at a lot of them. I've just never seen a Sahara that didn't have a Dana 44.