1987 Mj Project

[MichiganTrails87]

I purchased this truck about a year and a half ago and I've been slowly finding all the bugs. I'm starting to get to a point where it's reliable and road worthy.

1987 Jeep Comanche, long bed, metric ton edition (I think)
4wd, 4.0, AW4











I took out the interior of the Jeep last fall. The cabin floor is rotted but the truck bed looks almost new. I'm guessing the previous owner never took the cap off. I'm going to start floor repairs once it gets a little warmer outside.

I don't know too much about Jeeps but I do know from reading around this forum that this is a great community for Cherokee and Comanche owners. Hopefully this will be a great place for some advice.

The Bad:

-Fuel tank leaks when filled more than 75%
-Jeep is very slow. I'm guessing the tires are too large for the gear ratio
-Trans shift button isn't connected
-No radio
-Rusted driver's side floorboards
-Surface rust ... just a little everywhere in general
-Something wrong with the window cranks

Repaired last season:

-Radiator, hoses and transmission fluid lines
-Throttle Position Sensor
-New brakes ... everything basically
-New Shocks
-Lost of front suspension work completed

Previous owner said it was his fathers truck and had been sitting in a barn for 5 years. I'm hoping to complete a light restoration, stop the rust, and use it for light off-roading and moving materials/toys.

[GrumpysMJ]

From one newbie to another, welcome. I just got my first MJ, and I can tell you there is a lot of good info here, both from members and by going through old posts. I've picked up a lot of good info and tips.

Had the same problem as you, about my little 4 cyl being to "slow". Previous owner had put 235/75/15's on it which threw the gear ratio way off. Just put some 215/70/15's on it and now it scoots right along.

Have fun with yours, I am with mine.

GrumpysMJ

[MichiganTrails87]

Just a quick update, finally got outside and swapped out my rear diff oil. Cover had seen better days so I replaced that too.

 

 

 

 

 

Nothing terribly exciting, but progress!

[MichiganTrails87]

Quick beginner question everyone. My truck is a long bed and I need to replace the gas tank. It leaks when I try and fill it above 75%. I'm not sure what size tank this truck has. I took a tape measure out there and it looks like it's around 35" by 15".

 

 

 

 

I'm 90% sure this is a 23 gallon tank . Just want to know if there is a code or something I can check to make sure I order the correct one (3 tank straps vs 2?). I need the truck for a trip in 3 weeks to the smokey mountains and I can't afford to buy the wrong tank.

 

Also, everyone ordering these off of Ebay and Amazon? Is there a preferred place to purchase from?

 

Thanks in advance for everyone's advice.

[88whitemanche]

I'm pretty sure the o-ring on the electrical wires that goes to the top of the fuel sending unit gave out...it has happen to me you would have to replace that o-ring....there's a DIY way of refreshing your sending unit

 

The re-assembly of the senders brought a new problem into light - the 'o' ring under where the harness enters the top of the sender is unique. it is standard in size (ID and OD) but it's diameter (thickness) meant it was not standard. I finally found it at the local NAPA store - it unfortunately does not have a part number so you would need to take the old one in for comparison.

 

 

Then, fastening the push nut so leaks do not occur:

 

 

 

and finally, re-attaching the other wiring and taping the openings (keeps bugs out) for storage:

 

 

 

We bought new locking rings and 'o' rings for the senders - they are still commonly available but we got ours at NAPA: http://www.napaonline.com/Catalog/CatalogItemDetail.aspx?A=STPLO01_0261766611&An=599001+101989+50038+2038006&Ar=AND(P_RecType%3aA).

 

and, finished:

 

 

All-in-all, we spent about $60.00 for refurbishing the two senders.

 

My son's sender had developed a leak at the junction of the tube and the top (outside) plate of the unit - we ended up using JB Weld to repair his with good results. If either of the units here would have had non-working potentiometers I would have send them to the rebuilder, as adjusting the potentiometer is beyond the skills I have.

This the part I did on my truck and now I can fill up all the way!!!!! I've had that issue that I lost over a half a tank of gas. Smh

[MichiganTrails87]

I hear ya on losing most of a tank of gas ... I'm going to try rebuilding the sender unit. If it's too far gone I'm going to try and modify a Cherokee sender like MereAnatomy did with his Kentucky Bound page.

 

http://comancheclub.com/topic/32989-kentucky-bound-lwb/

 

Should make for a fun weekend. Also found some dry-rot on the tires from storing the truck this past winter. Looks like I'm going to CL to find some cheap used tires as well.

[MichiganTrails87]

Finally got some time tonight to work on the truck. Only 10 more days until the trip so I really need to get to work on this thing.

 

Started by hitting all the bolts with some oil. Don't think it's going to work ...

 

 

I also removed the filer neck and it's in decent shape. I'll need to wire wheel and paint it before replacing.

 

Got under the truck and the J-Bolts are completely stuck. After fighting with them for a few minutes, I started to just cut the straps. Got through the first one and the tank started to leak.

 

 

Now I have gas everywhere. With two straps still in place, I put a bucket under the tank leak and started to take the truck bed cap off.

 

 

I wish everything on the truck was as easy as removing those cap bolts. Truck should have plenty of room now for the motorcycles to fit.

 

I also washed, primed, and painted the new gas tank. Came out looking ok.

 

 

Wish I would have been able to get more accomplished but I suppose I should keep reminding myself that it's a 26 year old truck. Tomorrow the gas should be drained so I can cut the remaining straps and see just how rusted my sender unit is.

[MichiganTrails87]

I guess I should also ask, what do I do with about 3  gallons of rusty gasoline...