AEV Gladiator Rubicon

[Flyin6]

The more I look at this AEV suspension, the more I can see it is nothing special. Just some brackets, shocks, and springs. This is one of two brackets AEV used to just move both control arms to a lower point. Without them, I may have made up for the addition of weight from the heavier Clayton parts. The frame area sure looks cleaner without all that useless junk hanging there.

[Flyin6]

You can see the height difference here between the 2.5 AEV (Silver) springs and the new Clayton 3.5" Springs

[Flyin6]

More parts going on including the front track bar. The bends in it allow it to clear everything through full travel. The bolts holding the control arms are still loose.

I greased all the areas where the control arm bushings will seat.

[Flyin6]

I did not like the way the bump stop was installed as offered. You had to fish a nut to a spot that was all but impossible to get to. I bypassed all that, drilled the factory hole to 9/16", and installed a nut-sert on each side. That way I just screwed down the block from the top...Easy-peasy!

[Flyin6]

That cleared the way to install the two new springs

[Flyin6]

That led to shock time.

On the front, these Falcon shocks do not just slide into place. Because of the big precharge chamber. on the driver's side one needs to cut a hole into the inner fender liner. They supply a template to do that

[Flyin6]

The driver's shock has a lower offset bushing which I have never seen before. The bushing offsets the shock further away from the spring to keep it from touching during extreme flexing. This stuff is so well sorted out.

[stlaser]

During the gear swap would have been ideal time to swap the driveshafts.

[Flyin6]

During the gear swap would have been ideal time to swap the driveshafts.

Yep!

And I just figured out that when I jack the thing up and allow the rear suspension to droop, it falls so far now that the springs come out of the buckets that hold them. Found out also, that Teraflex makes a kit to positively retain the rear spring in the bucket. Would have been nice to have that here now as well

What's that they say about hind sight???

[stlaser]

During the gear swap would have been ideal time to swap the driveshafts.

Yep!

And I just figured out that when I jack the thing up and allow the rear suspension to droop, it falls so far now that the springs come out of the buckets that hold them. Found out also, that Teraflex makes a kit to positively retain the rear spring in the bucket. Would have been nice to have that here now as well

What's that they say about hind sight???

Limit straps….

[Nate]

Are you sure a set sidnt come in the kit somewhere?

[Flyin6]

Are you sure a set sidnt come in the kit somewhere?

No, and never heard of any such thing from them.

We have a new member, whom I just met over on a Gladiator forum. He suggested the Teraflex stuff that I'm going to take a look at. He also had some interesting ideas about the rear sway bar.

[Flyin6]

During the gear swap would have been ideal time to swap the driveshafts.

Yep!

And I just figured out that when I jack the thing up and allow the rear suspension to droop, it falls so far now that the springs come out of the buckets that hold them. Found out also, that Teraflex makes a kit to positively retain the rear spring in the bucket. Would have been nice to have that here now as well

What's that they say about hind sight???

Limit straps….

Is that what you are using on your JK?

[stlaser]

During the gear swap would have been ideal time to swap the driveshafts.

Yep!

And I just figured out that when I jack the thing up and allow the rear suspension to droop, it falls so far now that the springs come out of the buckets that hold them. Found out also, that Teraflex makes a kit to positively retain the rear spring in the bucket. Would have been nice to have that here now as well

What's that they say about hind sight???

Limit straps….

Is that what you are using on your JK?

Sold the JKU about a year ago. Some brewery in Florida bought it, but yes I used limit straps on it and do often to keep suspensions from destroying parts on full droop.

[Flyin6]

OK, let's get some more built on this JT

Today the goal was to complete the installation of the front suspension.

That started where I left off, installing the remaining front shock. Same-same as before, you need to modify the inner wheel well liner to fit the gas chamber of the shock. Falcon includes templates for the various models. Apparently, the Ruby fender/liners differ from other versions as evidenced by the multiple cutout templates available to the installer.

[Flyin6]

For the record, I recorded the starting shock settings. The lower half twisted to activate the "Performance range." The upper knob set to firm, position #3, and the micro knob is set to full soft, the bottom of the "firm range."

[Flyin6]

Next, I attached the brake line bracket extensions and mounted the lower brake line assembly to the lower control arm.

[Flyin6]

That led to the fitting of the front sway bar links.

To measure correctly, I mounted the end links onto their respective mounts, then marked the threaded rod, then cut that to length.

[Flyin6]

Some people are put off having to cut the sway bar end links to length, but I rather think it's a great idea. It allows for customization or other than factory alternatives.

This guy never seems far away.

His signature pose is when he crosses his front legs. I've never seen a dog do that naturally...

[Flyin6]

He loves riding around in my trucks and playing at the farm. I'm always afraid he will sink to the bottom of the pond, but so far, as you can see, he's made it!
With the end links installed, I went about tightening all the bolts and nuts everywhere and just like that I was done installing the Clayton suspension system, but, not done with the front end.

[Flyin6]

Next up will first be the Adams front double cardan, 1350 series driveshaft. I'll follow that by popping on a Yukon diff cover and set the thing down on the ground.

Oh and of course, I added the decals to increase horsepower, reduce weight, and lower my tax rate!

[Flyin6]

Today I finished the lift and installation of the Clayton overland suspension system. Actually, I finished that yesterday, but I still had to install the new Adams driveshaft since my lift is now beyond the stock driveshaft limits.

First I removed the numerous torx #50 bolts from the transfer case flange. I used a bunch of extensions and a 3/8" impact. That worked for all but one stubborn bolt.

[Flyin6]

Then I removed the front four-15mm bolts and pulled the old shaft

[Flyin6]

Here's a comparo of the stocker to the Adams:

[Flyin6]

The stock shaft had already elongated the boot sleeve and had some body damage from hitting on something. I can report having flexed the suspension to the max several times and that's where I may have picked it up. Thinking about it, the elongation may have been from simply installing the Clayton kit that droops tons past the AEV limits

[Flyin6]

You really get an appreciation for the quality of the Adams shaft and supporting parts. Just look at this zinc coated yoke. It's super clean!

[Flyin6]

Being a military guy, I don't get all the fascination for skulls and death. Hey, it will come soon enough, and most of the guys wearing patches, "Ts" and tattoos of skulls have no clue what a battlefield looks or feels like. But what the heck, do what you want.

[Flyin6]

Some more shots of the Adams shaft:

[Flyin6]

Next I found a 1 1/4" socket and with my impact gun, removed the stock t-case flange. It was not on there all that tight.

After removing the nut I taped it lightly with the brass drift and out it came.

[Flyin6]

I re-used the stock yoke retention nut, first giving it a coat of RTV, then first installing it with the impact, then torqueing to 166 ft/lbs.

Note: The impact did not achieve the full 166.

[Flyin6]

After tightening the front bolts, I greased the shaft. It took a bunch of grease, then I wiped some on the exposed splines, then wiped most of it off.

Then just like that the driveshaft installation was complete.

[Flyin6]

Except for bolting back on the wheels, I still had to install that Yukon front diff cover.

After filling with Lucas 85-140 I tossed on the wheels. I rotated all the tires during the install and even gave the whole vehicle a coat of that hydro ceramic wax stuff.

Sorry, forgot to snap the installed cover but it shows in the Hollywood shots coming up next.

[Flyin6]

And here it is all lifted to what I feel is the correct height with a real overland suspension and not some bracket cheapo thing.

[Flyin6]

The more I look at that AEV front bumper the more I have to wonder, "What were they thinking?" Not to be a downer, but look at how much of the grill is shrouded. That unnecessarily large hoop blocks what looks like a third of the airflow, and don't these things tend to run hot?

Well, it's a gonner. Will be saying bye-bye pretty soon.

Almost feel guilty wearing the AEV badging
Removed: AEV 4.56 gears
               AEV Wheels
               AEV 2.5" lift kit
               AEV Bilstein 5100 shocks

Still have the cool stripes, badging, that front bumper thing, a painted dash, painted interior panels, and AEV instrument cluster decals.

[Flyin6]

Getting to be the only proof:

[Flyin6]

Ducks, decals and Don as well as other things that begin with D are doing fine!

[JR]

That stand is nice.

[Atkinsmatt]

Lots of work but it looks great.

[Flyin6]

Lots of work but it looks great.

Tomorrow or the next day I'll find out how it rides

Alignment first

[JR]

Bet you drove it right away, but still have to feel it out some.

[Flyin6]

Bet you drove it right away, but still have to feel it out some.

I didn't
Finished it then pulled it outside without first bleeding the brakes. Waited for the kid to come home to help with that. Was 5ish by then and I was tired. Raining tomorrow, so maybe not then :-(

[Bob Smith]

You going to let a bit of rain stop you? If it isn’t raining, give it a few minutes.

[Bigdave_185]

And for sale sign goes in it when? 

Looks good better find some mall mulch beds to take some photos in.  Around here you could use a snow bank

[Flyin6]

If you can recall, this one started its life in the Daniel Boone National Forest. No mulch beds for the blue canoe.

Now the new Ram...That one, like your sweet 3500, is going to be a princess.

[Flyin6]

You going to let a bit of rain stop you? If it isn’t raining, give it a few minutes.

It cleared...Off to the alignment shop we go!

[Flyin6]

Well, actually, before I left for the alignment shop, I decided to start the next project: Rear seat removal. A couple of things: It's only going to be me and Kat. Possibly a grandkid, but, hey, I rode around in a truck bed when I was a kid...
Next, I will likely be carting a big hairy/messy dog, and he needs some space.
Then there's the weight savings. After removing those seats, I'm going to say before weighing them I just knocked off from 70-100 pounds. Man, they were heavy! Remember I have about as much horsepower as your lawn mower, so weight savings = horsepower.

Before I started:

[Flyin6]

Oh, and had to add to the decals which I am hoping are worth 3-5 HP each.

[Flyin6]

First up was to pull those heavy rubber floor mats

[Flyin6]

Then to pull a bunch of really tough to get out weird-headed bolts.

[Flyin6]

Then I wrangled the smallish seat that was made unusable when I added my front seat track extenders.