To prepare for a two-week winter 2026 expedition to Big Bend Ranch State Park and Big Bend National Park, I determined it was necessary to acquire a true four-wheel drive vehicle capable of handling a range of road and weather conditions. After conducting research and consulting with an experienced acquaintance, I selected a used Jeep CJ7 that required some refurbishment. With sufficient time and resources available, I promptly accepted delivery and commenced restoration.
The primary focus of the project was on establishing mechanical reliability rather than cosmetic enhancements. Special emphasis was placed on improving the engine and driveline to resolve performance concerns and ensure consistent operation. Additionally, the vehicle’s off-road capabilities were upgraded to enhance both safety and enjoyment while traversing the distinctive terrains presented by both parks and other off-road trails with friends and members of the Lone Star Jeep Club.
Over eight months and 700+ man-hours, plus several thousand dollars, restoration and upgrades thoroughly addressed the vehicle’s underside from front to back. The work included:
- Rebuilding the engine with new bearings, rings, timing chain, gaskets, flywheel, clutch, water pump, thermostat, alternator, and removing all emissions components.
- Removing the BBD Carburetor and installing a Holley Sniper EFI and Hyper Spark Ignition Systems.
- Rebuilding the Dana 300 transfer case with LOWMAX 4:1 gears, new bearings, seals, gaskets, and fitting a Novac Conversions billet aluminum cover.
- Replacing both the transmission cross member and its mounts.
- Completely rebuilding the front and rear differentials, removing the stock 2.73 gears and installing 3.54 gears with bearings and seals. The rear AMC 20 received an Eaton Posi-Trac Limited Slip Diff center section with Moser single-piece axles, while the front Dana 30 got an Aussie Locker, axle U-joints, bearings, seals, a modified Rough Country JK skid plate armor, and new locking wheel hubs.
- Installing a Brake Booster and remote air cleaner
- Repairing the original wiring harness.
- Swapping out all suspension and body bushings for polyurethane versions.
- Installing four new Ranchero shock absorbers.
- Replacing the front drive shaft and rebuilding the rear one.
- Fitting a Rock Hard front bumper with steering box armor option and Blue Ox adapters to permit flat towing when needed.
- Equipping a wireless-controlled winch rated at 10,000 pounds.
- Upgrading the damaged steering box mount to a Fishbone Heavy Duty version.
- Modifying the original rear bumper and fabricating a swing-out spare tire carrier with a winch.
- Installed 3-point seat belts
- Installing a custom Milwaukee Pack-Out storage system.
- Fabricated an adjustable front spring shackle chain to prevent the springs form spreading caused by the 2” lift shackles.
