Square headlights are better.

This is dedicated to the story of my 89 YJ.  This is my first Jeep.  I bought it from a family member for $500.  It wasn’t running when I got it… but I figured it would be a fun project.

I brought it home on July 1st, 2003.  Here is a pic…. It also came with full hard doors and a hard-top.

Cost me $300 for the tow dolly from Columbus, Ohio to Dallas, Texas.  So I guess it’s a $800 Jeep now.

I got it home, and looked over the receipts for the jeep.  It was apparent that the previous owner had replaced the tank, fuel pump, lines, cap, rotor, wires, plugs…etc… so I figured there had to be something wrong with the fuel injectors.  Sure enough, it was just the little O-rings above and below the injectors.  Someone had taken it apart at some time and put them in wrong.  I put them in according to my Haynes manual and off I went.

Can you believe they charge $16 for these little O-rings?  $816 Jeep.

July 5th, 2003:  Its got some bangups on it… plenty of rust (it started life in Canada) smacked up bumpers, etc…  I am working on beating out the fenders and going to install diamond plate corners in the rear after I cut out the rusted areas.  I found that Rustoleum “Sunrise Red” is a near perfect match for the paint!  $825 Jeep.

 

There was oil all over the engine, so I pressure washed it and changed out the valve cover gasket.  After about 30 miles, I saw where the “other” oil leak was coming from…. The timing cover to oil pan mating area.  So I pulled the front grille for better access, radiator, and ripped off the timing cover, pan, water pump, and t-stat housing.  Going to do a full re-seal and install a new water pump and T-stat.  $850 Jeep.

I also repainted the brake master cylinder cover.  The only real bling so far!  $853 Jeep.

I have been noticing a fuel smell around the car, so I pulled the gas tank.  Whoever installed it, crushed the vent lines, so they were leaking at the rollover valve.  The rollover valve boot has a big tear in it too, so that probably where the fuel smell is coming from…. It was never reaching the charcoal canister.  When I got the tank out, I also notice that someone had lost the rubber pad that protects the tank from rubbing on the gas tank skid plate…. And the new gas tank was already rusting at the contact points because of this.  So, off I go sanding and painting the tank and skid plates!  I went to Wal-mart, and picked up a few sheets of self-adhesive foam rubber sheets, and I cut these into 1.5” strips.  Then I will attach these to the inside of the skid plate.  Cost me $1.50 for the foam rubber sheets!  $855 Jeep.

 

 

I got some wheels and bumpers from a few fellow jeepn.com’ers.  Cant wait to get them on!  Biggest expense yet…. $1230 Jeep.  Ouch!

 

 

So, as of right now…. It’s all taken apart.  I am waiting on some gasket sets to come in for my timing cover, and all the paint to dry…. And I should begin putting it back together in a week or so!

Next on the list…. A bikini top, tires, and I am thinking about a 2.5” Skyjacker lift with hydros.  It also needs a floorpan in the drivers side… it’s a flintstone-mobile right now if I take the carpet out!

 

July 22nd 2003:  Got a one-piece rubber gasket for my oilpan, which was really designed for the 97+ TJ’s, but fits perfect on the older models.  Much easier to install, and better seal.  Installed the timing cover, water pump, thermostat, and t-stat housing tonight.  Hopefully will get to the oil pan tomorrow.  I also picked up a Bestop Bikini top today at Collinsbros Jeep.  $1415 Jeep.

July 24, 2003:  The oil-pan went on without a hitch.  I had to use some gasket adhesive to make it stay in place on the engine while I grabbed the pan and slid it up into place.  Slapped in the starter after that, and hooked it back up.  I swapped out the right motor mount tonight, planning on doing the left one ASAP.  After that, I will install the fan clutch/pulley/blade, and alternator.  Before I put the grill/radiator back on, I am planning on beating out the front fenders as good as I can, sanding them, priming, and then painting them.

July 25, 2003:  Got the left motor mount in.  Installed the fan blade/clutch assembly too.  $1438 Jeep.

July 27, 2003:  Installed fuel tank/skid plate.  Installed all new fuel lines and correctly routed vent hoses to the canister.  Installed rear tube bumper.

Primed and painted smashed rusty fenders, after I beat them back out a little.  $1450 Jeep.

 

July 28, 2003:  Installed grill, radiator, and shroud.  Installed belts, alternator.  New radiator hoses top and bottom.  Filled it with oil, water, and put 5 gallons of fuel in her.  Wont start!  L  $1492 DEAD Jeep.

July 29, 2003:  Well, I kept tracing the primary 12V+ wire from the pump, and sure enough, found a short.  I patched in a new segment of primary wire, and it cranked right up!  No charge!

July 30, 2003:  Took it for it’s first road trip since the teardown, to the JNT Sonic cruise-in.  Ran great all the way, but died on me about a block from my house on the way home.  Got a tow into my parking lot, let it sit for about 20 minutes, and then tried it again, and it cranked right up.  Damn this thing!  I checked voltage to the harness at the pump, and it is getting juice.  So now I suspect fuel pump or wiring between pump and harness.

Aug 3, 2003:  Been busy.  I found a short in the harness area of the tank, so I replaced all the wiring from the tank to about 4 feet out.  Replaced the primary 12V+ wire to the pump to about halfway up the vehicle.  Took it out, made it about a mile before it dies on me again.  This time, it would not start back up, so another tow home for my little red mule.  Got out the wiring diagrams, and kept working, until I found the culprit.  In the main engine compartment wiring harness, just to the right of the battery, there is a main splice that feeds the fuel pump relay.  The wires just crumbled off the splice when I moved them.  I replaced the splice using butt-connectors, I sure hope that was it. 

I tried to get the front bumper off, but one of the T55 torx heads stripped because it was so rusted.  I had to grind the head off, and the nut broke free from it’s tack-weld.  Got to find someone with a little welder to tack a new nut on there.  While I was there, I sanded the front frame areas and crossmember, and painted the entire area with a rust-converting primer.  It works pretty good!

Started on the drivers seat.  The sliders for the seat frame are busted, and had the wrong sized bolts holding it together.  It swivels left and right a few inches because of this, and was really annoying while driving around.  I need to get a new seat slider or try and get this one welded up with new bolts.

Aug 5, 2003:  Wire job seems to have fixed the dying problem!  Been driving her all over the place without any trouble.  Got a new nut welded to the frame and installed the new tube bumper.  Got my seat slider welded back together as well, so now it works great.  Took the vacuum 4WD actuator off the axle.  It was hanging up and not wanting to go in or out of 4WD very reliably.  Cleaned it and blew out the vacuum chambers.  Works pretty good now.  Got the windshield channel installed and put on the bikini top.  No charge!

Aug 15, 2003:  Jeep has been running great, driving it to work and back every day.  Replaced the gas cap.  Still smelling fuel on a full tank, and now I noticed the top of my tank is wet, and I am leaking fuel on turns.  Something must not be right where the fuel pump assembly mounts into the tank, so I gotta pull the tank again.  L  I will wait till I install the body lift, so it will be easier and have more room.  I pulled the diff cover, and painted it.  Cleaned the crap out of the rear end, and getting ready to re-assemble when all the paint dries.  Been soaking all the suspension in PB blaster, anticipating my lift installs.  $1500 Jeep.

August 20, 2003:  Diff project time.  Popped off the cover, drained fluid.  Didn’t look too bad, but needed a change.  Sprayed it out with brake cleaner.  I sanded and painted the cover while I had it off, and the bolts.  Looks nice!  $1512 Jeep.

 

August 27, 2003:  Put the front two tires on my new wheels…. Eagle 589’s, I picked up used.  I had some Canyon Crawlers, but I decided I wanted wheels with less backspacing, so they would stick out a little, for a wider stance and less rubbing issues at full turn when I go to bigger tires.  Tires are Goodyear 31x10.5x15 MTR’s.  I am waiting on the back two tires, Discount had to order them, so I took off the brake drums, wire brushed all the rust and scale off, and painted them.  Before and after shots:

 

August 28, 2003:  Damn tires cost me $280 for two…. L  Put all the tires and wheels on and took it off the jack-stands.  Damn, it is looking good these days!  Replaced a headlight, and installed new wiper blades.  Now I am CRAVING a lift… these 31’s don’t rub on turns, but they hit my flares when I go over a speed bump!  $2000 Jeep as it stands today!  Here is how it looks with the new meats, no lift yet:

Sept 04, 2003:  Got my lift kit in today.  Ordered a BDS 2” suspension lift, BDS shocks, Rough Country steering stabilizer, MORE 5/8” boomerang shackles front and rear, MORE 1” body lift system with new body mounts.  Began installing it tonight.  Man, this rust is killing me!!!  Here are some pics of the lift:

Sept 05, 2003:  Still working on taking stuff off.  My front shocks were so rusty, they took forever.  Would have been faster just to cut them off, but I don’t have a saws-all or a cutoff.  The shackles came loose no problem, but the other ends are awful… the bolts just don’t want to come out, they are vulcanized to the rubber bushings.  I am getting them slowly but surely.  Finished the front left side tonight, almost done getting the right spring off.

Sept. 10, 2003:  Lift install has been slow going.  Had to cut the rear bolts on the front springs, and the front bolts on the rear springs, and buy new bolts.  Spun a nut in the frame of the TC skid.  Broke the torque arm bolt which holds the rubber bumpers for the torque arm of the TC to the skid.  Had to beat out the rear trackbar bolt with a sledge.  Rust has plagued this install.  PB blaster is not really impressive.  I completed the front lift a few days ago, and right now am about 80% done with the rear.  Springs are on, just need to bolt up the new shocks, and mount the tires.  I pulled the gas tank because of the ongoing leak it has had at the sending unit seal….. will try to get that fixed before I re-install it.

Sept. 11, 2003:  Finished the suspension lift!!!  I also installed a new beefy steering stabilizer.  Got started on the 1” body lift.  I broke one bolt, and one of the body mount frame nuts is just spinning.  L  Going to have to bust out the drill soon.  I also fixed the fuel tank leak, by installing a new sending unit O-ring gasket.

Sept 15, 2003:  Finished installing the 1” MORE body lift and new MORE body mounts.  Looks great!  Also installed a used soft top I picked up.  Installed bumper mounted 5” off-road lights, and a relay to the factory fog-light switch.  Just a couple more things and I am off to the trails with my heap.

Sept 28, 2003:  Installed Teraflex swaybar quick-disconnects.  Removed my front and rear tracbars.  Went wheeling for the first time!  The jeep did awesome.  Really climbed, and handled everything as I expected it to.  I am really impressed with these BDS springs, MORE shackles, and MTR’s!  Here is a pic:

Here are a few more current pics:

http://www.advantexcom.net/~quino/jeep2/YJ1.jpg

http://www.advantexcom.net/~quino/jeep2/YJ2.jpg

http://www.advantexcom.net/~quino/jeep2/YJ3.jpg

http://www.advantexcom.net/~quino/jeep2/YJ4.jpg

http://www.advantexcom.net/~quino/jeep2/YJ5.jpg

 

 

“The” list:  Some done…. Some to-do.

1.      Replaced injector O-rings

2.      Replaced throttle body base gasket

3.      Replaced valve cover gasket

4.      Removed, sanded, painted gas tank and skid.  Install new bolts.

5.      Tweaked fuel tank sending unit so it reads “more” properly.

6.      Sanded and painted rear frame bumper attachment.

7.      Beat out dented front fenders.  Sanded and painted front fenders.

8.      Re-sealed oilpan and timing cover

9.      Replaced motor mounts and tranny mount.

10. Replaced gas cap.

11. Repainted brake MC cover.

12. Removed, painted, and reinstalled thermostat housing with a new thermostat

13. Removed old water pump.  Painted, then installed new pump.

14. Installed fuel pressure Schrader valve on throttle body.

15. Installed new interior light bulbs in Tach and Speedo.

16. Replaced several fuel pump wires, and repaired main engine wiring harnesses connections.

17. Replaced broken and aged vacuum lines.

18. Replaced PCV valve.  Cleaned oil out of airbox.

19. Painted bellhousing dust-cover.  Painted harmonic balancer.

20. Replaced top and bottom radiator hose.

21. Repaired fuel return line back to stock condition

22. Welded/repaired drivers seat frame.

23. Painted brake drums

24. Replaced all fuel vent lines from tank to canister.

25. Flushed and refilled rear differential fluid.  Sanded and painted rear diff cover.

26. Removed and pitched beat-up stock bumpers. 

27. Added lock washers to starter bolts (they were too long and not seating properly)

28. Cleaned 4WD front axle actuator, cleaned all the vacuum lines and fittings.

29. Installed bikini top.

30. Replaced left headlight.

31. Replaced left taillight.

32. Replaced wiper blades.

33. Installed Alloy wheels and new 31x10.5” tires.

34. Installed black tube bumpers front and rear.

35. Installed 2” suspension lift.

36. Installed new shocks and steering stabilizer.

37. Installed MORE boomerang shackles.

38. Install 1”body lift and new tub body mounts.

39. Installed Teraflex quick disconnects on the sway bar.

40. Removed front and rear trackbars.

41. Install CB and antenna

42. Installed off-road lighting

43. Cut out rust in rear body corner.  Cover with diamond plate covers.

44. Replace front brake calipers, flush brake fluid.

45. Install center console and some kind of decent stereo system that wont just get stolen.

46. Clean engine internally and change oil.

47. Change all fluids in tranny, transfer case, and rear-end.

48. Get some RXP gas treatment

49. Pray it will pass emissions inspection!