1991 MJ(s) | Project Moe

[87Warrior]

I was awarded the opportunity to pick up a 1991 4.0 and a 1991 2.5 from Geonovast, so a buddy and I made a trip to Central Missouri to meet up with Correy. After a few road construction delays and a few gallons of diesel fuel, we arrived an hour later than planned at the Walmart in the town the MJs resided in. Correy led us through several miles of back roads around the Lake of the Ozarks in the Ozark mountains. I was thoroughly enjoying the scenic drive when the MJs popped into view. While excited about getting to check out the trucks, I was a bit disappointed the exploration journey had ended.

 

After an hour or so, and after working Correy's XJ, the two gems were loaded up without any damage. The trucks were exactly what I was expecting to find based on the descriptions Correy gave me.

 

Here we are, all loaded up and settled. Now we had to find our way out of the Ozark mountains. As the Cummins lugged down the narrow road, we noticed a quickly approaching XJ from behind. It was Correy! It seems we forgot to retrieve the keys.from him. Whoops.

 

The Cummins pulled the trailer and trucks with ease. I am continually impressed with that Dodge. The drive back to central KS wasn't that exciting with the exception of our one stop for dinner at Hardees in Nevada (pronounced Ne-Ve-Duh), MO where a lady in the drive thru was fired up. Here we are stopped for Hardees.

 

Once back in the flat lands of Kansas, the trucks found their temporary resting spot in the back yard until u get a windshield installed in the 86 so it can come out of the garage.

 

The project name 'Moe' is a tribute to the trucks previous resting place in Missouri and their previous owner Correy. Silly? Lame? Goofy? Maybe, but fitting.

 

Stay tuned for updates as I establish my goals and objectives for these trucks. :thumbsup:

[COFFMAN]

:popcorn:

[Zenobian_84]

Not sure if I missed this, but is the no-frills red one the 91, and the AMC Blue one the 87? Both are pretty decent looking trucks :yes: :wrench:

 

Will be watching with much interest. :popcorn:

[87Warrior]

Not sure if I missed this, but is the no-frills red one the 91, and the AMC Blue one the 87? Both are pretty decent looking trucks :yes: :wrench:

 

Will be watching with much interest. :popcorn:

Both trucks are 1991 model year :brows:

 

Here are the specifications I know

 

Red

1/2 of a 2.5 (head was pulled)

AX5

231

30/35

Moon roof

Bench seat

Bed seems to be rot free, but the rockers and cab corners are disappearing

Rear axle won't let the truck roll forward, but it free wheels backwards.

 

Blue

4.0 with a chewed on wiring harness due to a rat

AC/Cruise/PS

AX15

231

30/35

XJ fuel tank in the bed

MJ buckets with console

Frame has rusted in 3 large areas. Rockers are gone as are the cab corners and lower portion of the doors. Bed is typical of MJs in the salt belt.

[Zenobian_84]

:doh: Not sure how I completely missed that. Still, not a bad haul :thumbsup:

[500 MJ]

Blue

4.0 with a chewed on wiring harness due to a rat

AC/Cruise/PS

AX15

231

30/35

XJ fuel tank in the bed

MJ buckets with console

Frame has rusted in 3 large areas. Rockers are gone as are the cab corners and lower portion of the doors. Bed is typical of MJs in the salt belt.

 

I helped pull the 2wd AX-15 from this truck. It is still sitting on my shelf for a future trans for my 2wd MJ AW4 to AX-15 swap. I have the matching driveshaft for it as well. I guess I'm just vouching that the truck originally was 2wd...

[dualthrush2s]

nice into love cummins :popcorn:

[87Warrior]

I helped pull the 2wd AX-15 from this truck. It is still sitting on my shelf for a future trans for my 2wd MJ AW4 to AX-15 swap. I have the matching driveshaft for it as well. I guess I'm just vouching that the truck originally was 2wd...

Good to know. I knew that a few members had time time invested in the truck. I was aware that it was in mid 4x4 swap.

[Automan2164]

Good deal. Along with Brent, we all have a little tinker time with these. If Correy would have been closer, I'd have been all over that 4 cyl. It would be a perfect DD.

 

Sounds like it worked out well for the both of you. I'm sure Correy feels a whole lot better knowing they found a home with someone like you.

 

Subscribed.

Rob :cheers:

[buxmj]

Hey Brett, awesome adition to the fleet, does that make 4, 5 or more? Hope you guys get some rain soon. I was in KC last week and I never remember it being that dry, horrible. How's the paint coming along on the red one?

Buck.

[87Warrior]

Gosh, time flies when you are swamped with work and two other MJ projects!

 

New front axle acquired:

-1995 F350 (balljoint) Dana60 with 4.10s

 

It was darn heavy, so my buddy helped unload it:

 

New rear axle acquired:

- 1981 to 1983 F350 Dana 61FF with 4.10s and LSD

 

It was part of a frame that was laying behind my buddy's shop. It was nasty!

 

Pulled it apart:

 

New bearings and stuff:

 

Chevy disc brakes:

[COFFMAN]

Thinking this will be a cool build, but don't forget about the red one.It was stumbling across that build on another fourm that started my addiction.

Love ya mobile diff stands

[87Warrior]

Thinking this will be a cool build, but don't forget about the red one.It was stumbling across that build on another fourm that started my addiction.

Love ya mobile diff stands

Thanks. Axles are just plain heavy and a pain to move around by yourself, especially if they are 1 tons. I needed them portable since I am working in my, full, garage. I have also been hammering out a cross member design that utilizes the Ruff Stuff 3-Link kit brackets. Kind of a Clayton/Synergy hybrid.

 

Oh and don't worry, the '92 is still underway (I just can't find a mint set of 97+ fenders to finish the paint).

 

I wrapped up the hubs this evening on the D61 after locating a pair of the nylock spindle lock nuts. It has come a long way since it was drug out of a farm scrap pile.

 

And a detail of the Ruff Stuff disc brake caliper brackets:

(yes, I know the guide pins are not completely seated)

[87Warrior]

Its time for the trucks to get a little love. I have spent the past couple of weeks really combing over the trucks to get a better idea of what I am working with. Here is a quick rundown of what I found after a thorough inspection.

 

Red

Under hood wiring harness has a good chunk chewed through

Unable to locate most of the 2.5L drive accessories

Solid frame with rotted floor

Shattered spider gears in Dana 35

Worn out bench seat

Rotted cab corners

 

Blue

Found a 3' long section of frame missing on the passenger side along with 2 holes in the driver side frame

Rotted floors

4.0 would not turn over with breaker bar

Dirty, but solid buckets

Rotted rockers, cab corners and door

 

The plan: Build the red truck. Swap the good 4.0 wiring harness over and install a good 4.0.

 

Progress:

Stripped the interior from the blue truck-

 

Then pulled the red truck to the garage and parked it in its, more permanent than temporary, parking spot-

(Since it is still winter, my wife demanded that her car still gets a spot in the garage. My poor TJ is now parked under the back deck!)

 

Next up: Pull both drivetrains and start the 4.0 swap!

[87Warrior]

As luck would have it, work has been keeping me busy until dark with this nice spring like weather. Not to be deterred from progress on this project, I decided to retrieve the 4.0/AW4/231 combo sitting in storage. Diesel fuel and hydraulics make the process much easier:

 

Image prior to unloading the following day. The ol' 86 did have a good lean going on:

 

Then I pulled the drivetrain out of the project truck:

 

Here are the two most common Comanche drivetrains sitting side-by-side. Once the two were sitting on the garage floor my wife came out to see the progress. Pointing to the 4.0, she asked, 'Will it fit?!?'

[87Warrior]

Another one bites the dust:

She put up a fight letting go of the drivetrain. It all started with the transmission cross member that was welded to the frame. Then when attempting to remove the frame horns one wouldn't budge. It too was welded to the frame. 

 

Waiting for the 2.5 drivetrain to join:

(no,no,no.... they will be going to storage, not scrap)

 

My next step is to repair the 4.0 wiring harness. A number of wires have either been chewed through or simply worn through over the years. I have already removed surface rust from the frame rails and painted the area in preparation for the 4.0 frame horns. MORE motor mounts will be bolted to the 4.0 frame horns. I also need to drill out a few broken bolts still stuck in the frame for the cross member as well as clean and tap the frame nuts. While I won't be using the stock AW4 cross member with this build, I want it to mount up without an issue so I can get accurate measurements. 

 

I will also be fitting a 97+ brake booster and pedal assembly in the truck. The late model boosters are more powerful and will work better with the 99 Dodge 2500 master cylinder that will be pushing fluid to the massive Ford brakes. A simple proportioning valve will control fluid to the rear axle.

[87Warrior]

I had to open up a garage bay for my wife's Camry since we are forecasted to get 7" of snow this weekend.

 

Cleaned up frame rail and motor mount frame horns:

 

Chained up. Ready, Aim, Fire!

 

....and the six fits!

[Geonovast]

I think I'm gonna cry, Brett.

[Alexia]

I think I'm gonna cry, Brett.

The only way to relieve the pain is to buy another Comanche.

[87Warrior]

:agree:

 

I think I'm gonna cry, Brett.

:eek: Hopefully not tears of sorrow  :???:

 

I have 3 MJs and my TJ surrounding my garage right now. Earlier this week a fellow pulled into my my driveway right as I got home from work. He was from the next county over, just passing through the country side and asked if I liked these Jeeps. I assured him I did and he passed along a phone number for his buddy in town that has a rusty, green, MJ with a good motor and a bad transmission sitting around that he would entertain getting rid of. I have no clue about the specifications, but I have seen the truck behind a fence before. It is forest service green with a white topper. I need to call the fellow tomorrow.

[neohic]

I have 3 MJs and my TJ surrounding my garage right now. Earlier this week a fellow pulled into my my driveway right as I got home from work. He was from the next county over, just passing through the country side and asked if I liked these Jeeps. I assured him I did and he passed along a phone number for his buddy in town that has a rusty, green, MJ with a good motor and a bad transmission sitting around that he would entertain getting rid of. I have no clue about the specifications, but I have seen the truck behind a fence before. It is forest service green with a white topper. I need to call the fellow tomorrow.

 

Do we have another Jim Oshel in our midst?  :D

[87Warrior]

There is only one Jim. A fellow like me can only dream of living up to his reputation!

[87Warrior]

I am making progress once again.

 

I noticed the heater core tubes were a little smashed up so I elected to go ahead and replace it. 

 

Old vs. new replacement

 

I then worked on getting a bigger, better, power brake booster in the truck. This is from a '98 XJ. I also retrofitted the '98 brake pedal assembly to work with the pre '97 dash and firewall assembly.

 

After spending hours upon hours studying the wiring diagrams in the FSM, I was able to repair the 4.0 wiring harness that some rodents destroyed. Slowly getting everything put into the engine bay. Notice the jug of, "you'll thanks me later" sitting on the radiator  :bowdown:

 

I also did the 'Hornbrod' dual auxiliary fan mod: http://comancheclub.com/topic/7895-dual-oem-aux-fan-installation/

I am still undecided on what fan control I will use.  :???:

 

She is getting real close to starting. I can hardly wait until it fires for the first time  :laughin:

[87Warrior]

.....and it lives!

Youtube video of the first attempt at getting this 200K mile 4.0 to start. No CEL, thank goodness!

 

 

Safety tip. Make sure the auto transmission is in park. It wasn't, and allowed the t-case to dump its contents on to the garage floor since there is no yoke in the slip joint  :doh:

[Geonovast]

I can't believe you made her an auto. :oops:

 

Did you figure out what was wrong with the 4.0?  Last time I tried to start it, nothing would happen, but the motor still turned over with a ratchet.  Figured it was a wiring issue.