Unleashing My Jeep: The Ultimate Willys EcoDiesel Build for the Rubicon Trail
- Muddy Ruttzz
- 23 minutes ago
- 8 min read
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What You Will Find In This Blog Post:
It’s officially time to take my 2020 Jeep Wrangler to the next level. After sorting out the death wobble on my wife’s Gladiator and getting my mind blown by the rigs at Overland Expo West, I had a serious choice to make: drop major cash on an Ineos Grenadier or a used Rubicon, or invest that $15,000 budget right back into a dedicated Willys EcoDiesel build. I chose to build. Over the last 40 years of turning wrenches and working with sheet metal, I’ve learned the absolute value of knowing every single nut and bolt on a machine. I've babied this Jeep since day one, and rather than inherit someone else's mechanical headaches, I’m transforming it into a Rubicon-ready monster right here in my Las Cruces garage.
This transformation isn't just about slapping on some 35x10.5 Kenda Klever RT pizza cutters on Black Rock steelies, though that classic look is a massive part of it. We are doing this right. That means pulling in top-tier components like Metalcloak upper control arms to dial in the caster angles for the 2-inch Mopar lift. The patented Duroflex joints on those Metalcloak arms are going to give this rig massive, bind-free articulation while keeping the on-road ride smooth. While I'll be handling the heavy lifting and DIY upgrades, I'm also bringing in the pros at Premier West Gears to ensure the factory Dana M210 front axle and the rear end are properly re-geared and locked for maximum traction.
If you stick around for this series, you’ll get a front-row seat to the entire process. From desert shakedown runs towing my Xventure off-road trailer to eventually crawling the iconic Rubicon Trail, we are turning a proven daily driver into an unstoppable overland Jeep build. Read on to see exactly how this project is taking shape, and check out the video to see the heavy lifting begin.
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The Vision: Starting My Willys EcoDiesel Build
I decided to build a Rubicon-ready beast! What sparked this idea? Well, it was hard not to be inspired by those super cool and capable Jeeps and Grenadiers I saw at Overland Expo West. Plus, my buddy who tagged along kept raving about how much he loved my Jeep. It really shined when I towed my Xventure trailer to Alstrom Point on Lake Powell and cruised through the Grand Staircase Escalante.
Honestly, I wasn't too keen on dropping $90K on an Ineos, but I definitely wanted something beefier than my Willys. I played around with the idea of selling it and upgrading to a Rubicon, which would give me features like lockers, wider axles, and a sway bar disconnect. That would have set me back about $15K. In the end, I figured it made more sense to invest that $15K in upgrading my 2020 Wrangler's EcoDiesel instead.
The Look: Black Rock Steelies & Pizza Cutters
Would I liked to have bought some AEV or Method wheels? You bet but I have a love of steelies and this Willys Rubicon Killer Project has a limited 15K budget. The perfect compromise without compromising? Black Rock 997 Type 8 Steel Wheels made right in California USA. I paired them with a set of 5 Kenda Klever RTs sized 35X10.5X17 Pizza Cutters. Both are budget friendly but durable high performing choices.
Great Selection of Black Rock Steel Wheels Available on Amazon
Great Selection of Black Rock 997 Type 8 Wheels Available on eBay
Lessons Learned from the Gladiator Rubicon
This article and video is all about showing love to my Wrangler Willys Ecodiesel but I spent months in a knockdown-drag-out fight with death wobble on my wife’s Gladiator Rubicon. I won that battle—you can check the playlist in the card above. It’s ready for Moab in October, but that’s her rig. Out of respect, I only drive it from the passenger seat.
Build vs. Buy: Why I Chose the Willys Over a New Rig
The 2 vehicles pictured above got me thinking it was time for me to upgrade my dedicated off-road vehicle. When I mentioned to my buddy I was ready deal for a new Grenadier he kept reminding me what a cool rig my Wrangler Willys Ecodiesel is. When I got home I bounced around a lot of ideas about new rigs but everytime I jumped in the Willys it just felt right. I crunched the numbers and realized $15K in mods was a lot cheaper than $90K for new rig. That's when I developed my plan to transform my Willys Wrangler into Rubicon Killer. Once you factor in the purchase price, the potential unknowns, and the risk of inheriting someone else’s mechanical headaches? Forget it. My Willys has been babied for six years. I know every bolt on this thing.
DIY Mechanics and Professional Axle Upgrades
The OEM plastic lined ball joints definitely had to go. I bought some Synergy HD units. I knew it was going to take some DIY and help from professionals to get this rig modified right. I know when to DIY and when I should hand off a project, (usually.) Ball Joints I can handle, re-gear and lockers? I need the pros to assist.
Bulletproofing the Dana 44 M220 Rear & M210 Front Axle
Premiere West Gears, SoCal's best? I drove 700 miles each way to find out for myself. In the short lived run of Ecodiesels Jeep produced all were equipped with Rubicon Axles. The difference? Sport model Ecodiesels have the Narrow Track European style Rubicon Axles and the Rubicon models have the wide track Dana 44s. Those OEM Dana 44s are plenty strong but when you're building a Willys Rubicon Killer, axles are a key upgrade.
The Premiere West Parts List:
Dana Spicer REM Polished Ring and Pinion: Premiere recommended I go from the OEM 3.73 gears to 4.10.
Eaton Electronic Lockers: The OEM limited slip in the Willys is pretty good but no Rubicon conquering build would be complete without a sel to locking axles.
RCV Front Axle: Super strong axles with lock to lock turning ability. I'm intersted to see how these work out for me.
Revolution Rear Axles: Take a already strong Rubicon Axle and swap it out for Revolution units. That's a winner.
Avoid Limp Mode, Warning Lights, Sluggish Performance, and Bad Shift Points
Let me tell you about this ECRI Calibration Device—it's a game changer! After the crew at Premier West Gears finished re-gearing, installing my locker, and getting my axles sorted out, I had a 700-mile trek ahead of me from Southern California to New Mexico. I really wanted my Jeep to feel right on that long drive, and luckily, I remembered to bring my ECRI along for the ride.
What’s great about this device is how it works: you buy it once, pay per VIN, and then you can use it over and over again. So, once you’ve got it, it’s good for all your vehicles—and even your friends' rides too! Everything is handled through the ECRI App, including payment. I paid for my Wrangler the first time I changed tire size, and now I can recalibrate things like Axle Ratio anytime I need to. I actually did that right before I hit the road from Premier's shop. Super convenient!
Dialing in the Suspension: Metalcloak Upper Control Arms
You can't go wrong with MetalCloak and that is probably what I'll choose to replace the OEM suspension on the Willys Wrangler Ecodiesel Rubicon Killer Build. The photo above shows the parts I installed on the Gladiator. That build came out so good I can't really see any reason for going with any other parts. This phase is a way off so I'll keep an open mind to others manufacturers but at this point, MetalCloak is in the pole position.
Conclusion: The Roadmap: From the New Mexico Desert to the Rubicon
We have a trip to Moab with the Jeep Jamboree scheduled for late October and we'll be in the Gladiator with my wife behind the wheel. A fringe benefit of attending Jeep Jamboree events is you get on the advance list for the next years reservations. When it comes time to sign up for the next Jamboree I'll shoot for the Rubicon trip. By then I'll have the Wrangler Willys Rubicon Killer Build totally dialed in and we'll have a Rubicon capable rig. Of course, my wife will be behind the wheel for that one too.
I know along the way just like any project there are going to be surprises or what you might call Scope Creep. I'm sure I will find out I need more parts and mods than I bargained for. I'm just hoping I can stay close to that original $15K budget.
Muddy Ruttzz is a digital creator, overlander, and DIY enthusiast who documents rugged outdoor adventures and the gear that makes them possible through the Muddy Ruttzz brand. With a multi-decade background in industrial sheet metal fabrication, heavy infrastructure construction, and mechanical problem-solving, he brings a straightforward, hands-on trade perspective to technical builds, vehicle modifications, and digital workflow optimization.
#WillysEcoDieselBuild #JeepBuild #MuddyRuttzz #RubiconReady #Overlanding #JeepWrangler #Metalcloak #PizzaCutters #BlackRockSteelies #OffRoadLife #EcoDiesel
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