WJ swap with OTK steering

[PopLockLSwap]

Gearing up to do a WJ knuckle swap and trying to piece together what I need for everything to try to make it as smooth as I can.
Currently the jeep has 4.5" lift with an IRO 3 link long arm kit. Jeep is an all rounder with daily driving and trails. She gets used for sure.

I've got the knuckles and the brake system pretty much dialed in, I Would like to try and get some insight on what everyone thinks of some of the OTK steering systems out there. Everything from Cavfab, SFR, Ironman4x4, there is just so many different options. OTA track bar is something else that will be getting installed with the steering setup to ensure angles and such are happy.

I've been leaning more towards Cavfab's OTK WJ steering and OTA track bar with the brace, Not too worried about heims it comes with I've heard they make noise, but I currently have a Synergy 1 ton setup on it right now and it makes some noise meh. Also considered leaning towards SFR high roller WJ kit with track bar/brace. I know that comes with 1 ton TRE's which is also fine, just want to get a few peoples opinions on what they've installed and how they like them.

I've also seen CORE4x4 total WJ swap kit. Seems like it has everything but there's the price they're asking for it. Also don't know if I like the sport trac rotors it comes with as I'll need to machine my hubs or spend 150 and buy theirs.

Anyways thanks for the input y'all!

 

[75SV1]

OK, I've done two of them. Also, redid one of them to a 5 on 5. I used Ruff Stuff's 1-tom GM cross over kit. Also, Rusty's OTK trackbar. There weren't many options back then. I liked it. I did some green orange trails with it. It tracks straight and handles very well on roads. I also use 07-08 Dodge Nitro or Jeep Liberty rotors.
My present XJ, I have is mainly SFR components. I like his brackets. 1/4 steel. I pieced together the steering linkages. I needed to use some offset TREs on this one.
I used Mevotech TTX lower ball joints on the first one. XFR's on the second one.

I do have Ironman's OTK. I have not installed it. Something about the bracket to the axle didn't work out for me.

I might try a Teraflew ball joint in the future. The position of the grease fittings are more accessible.

 

[PopLockLSwap]

OK, I've done two of them. Also, redid one of them to a 5 on 5. I used Ruff Stuff's 1-tom GM cross over kit. Also, Rusty's OTK trackbar. There weren't many options back then. I liked it. I did some green orange trails with it. It tracks straight and handles very well on roads. I also use 07-08 Dodge Nitro or Jeep Liberty rotors.
My present XJ, I have is mainly SFR components. I like his brackets. 1/4 steel. I pieced together the steering linkages. I needed to use some offset TREs on this one.
I used Mevotech TTX lower ball joints on the first one. XFR's on the second one.

I do have Ironman's OTK. I have not installed it. Something about the bracket to the axle didn't work out for me.

I might try a Teraflew ball joint in the future. The position of the grease fittings are more accessible.

Awesome thanks for the info! I know now there's tons of info and kits and 100 ways to get the job done and to be honest it's all almost overwhelming. I know the cavfab would be least expensive route, and it comes with heims, and SFR is also up there in price at a few hundred more but I believe it has the actual TRE's which is also nice since the jeep itself is a daily.

Just wanting to gauge what other people have done and what their experiences are with it.

I saw a set of dana Spicer BJ's on rockauto and was leaning towards those. My jeep is on 33's and I don't see myself going any larger.

 

[JonnyCat63]

On my 99XJ, I did the WJ knuckle swap. I had Parts Mike out of Northern California make up my drag link, tie rod, and track bar. They'll machine and thread any size DOM you want, just give them the measurements.

You'll almost assuredly need to make a custom track bar, as you angles won't line up with the stock axle brackets. For the track bar I used SFR's frame side mount, For the axle side I also used SFR's mount. Since I'm running and IRO truss up front, I had to modify the axle mount a bit. For each end of the track bar, I used Johnny Joints. I just cut off my sway bar mounts, as it it mostly a dedicated trail rig.

For the drag link, I used a high angle drag link at the pitman arm, I think it is ES2027. Can't remember what I used at the knuckle, whatever Parts Mike recommended. All the TRE's are GM 1 ton. For the tie rod, I used offset TRE's. With the Ruffstuff diff cover I'm running, I had to use offsets.

It steers and rides great, really happy with my set up. I'm running the IRO 3 link, too.

 

[PopLockLSwap]

On my 99XJ, I did the WJ knuckle swap. I had Parts Mike out of Northern California make up my drag link, tie rod, and track bar. They'll machine and thread any size DOM you want, just give them the measurements.

You'll almost assuredly need to make a custom track bar, as you angles won't line up with the stock axle brackets. For the track bar I used SFR's frame side mount, For the axle side I also used SFR's mount. Since I'm running and IRO truss up front, I had to modify the axle mount a bit. For each end of the track bar, I used Johnny Joints. I just cut off my sway bar mounts, as it it mostly a dedicated trail rig.

For the drag link, I used a high angle drag link at the pitman arm, I think it is ES2027. Can't remember what I used at the knuckle, whatever Parts Mike recommended. All the TRE's are GM 1 ton. For the tie rod, I used offset TRE's. With the Ruffstuff diff cover I'm running, I had to use offsets.

It steers and rides great, really happy with my set up. I'm running the IRO 3 link, too.
View attachment 12755View attachment 12757View attachment 12758

I love the look of that front axle, very clean. Also did not know about Parts Mike so that's an option as well. I'd have to remount the sway bar mounts but that can be done as an after fact. I've talked with Casey from Cavfab and they do have a kit that would work for what I'm wanting to do, just don't know about having heims in there. Thought about adding boots to the heims to protect them some since they're exposed but idk.

I do like the look of the stinkyfab kits and have honestly heard great things about both companies.

The good news is I can have the jeep down for a bit while planning and measuring stuff out so it's not a huge deal.

 

[Doc Payne]

On my 99XJ, I did the WJ knuckle swap. I had Parts Mike out of Northern California make up my drag link, tie rod, and track bar. They'll machine and thread any size DOM you want, just give them the measurements.

This is really helpful info. Do you remember the rough cost to have these made up?

 

[JonnyCat63]

This is really helpful info. Do you remember the rough cost to have these made up?

I pulled out the receipt. This was in 2020, so I'm sure the costs have gone up.

This was for 1.25'OD DOM tubing, .250 wall, threaded on both ends. For the tie rod and drag link, it was $90.00 each, plus tax and shipping.

I bought some tie rod ends and some Johnny Joints from him, too. He even made me some custom spacers, too. It was like around $550.00 for everything I bought. I thought their prices were very reasonable.

Parts Mike was really helpful and knowledgeable. I spoke directly on the phone with someone there, too. They were great. I think they even gave me a discount for mentioning I was a member.

 

[75SV1]

I used the Rough Stuff kit :

GM Crossover Steering Kit

Check out the deal on GM Crossover Steering Kit at RuffStuff Specialties

www.ruffstuffspecialties.com

I think it was $250 or so, about 10 years ago. Then there's welding etc.