8valvehero Posted August 10, 2017 Share Posted August 10, 2017 Hey gang It feels like just yesterday that I joined the CC family, but here I am welcoming my third MJ. I scored a fantastic deal on a project with a solid base: 1991 LWB AW4 4WD bech seat D44 with only 120k miles on the clock! Ownership is clean and I can't believe my luck. I work at Mt Baker Ski Area and a local found out that I was in to Jeeps. He sought me out and made me an offer I couldn't refuse. First look: The rust is prolific, but merely superficial. The floors are intact, but she needs 2 windows, both doors need hinge repair and nothing works. If she had been left to sit in the forest for another year or two she would have been gone. I saw right through all of that and immediately fell in love. In the several months since then, I have been pushing back the hands of time and neglect. I will get caught up in the next few posts. Here's what I've done so far besides standard tune-up stuff (current 10/2017): Replaced fuel tank. Replaced PS door hinge pins. Welded DS door hinge. New door checks. 4/1 leaf springs (w/ extra helper springs) from donor & new bushings. (+ 2.5"rear) 2" spring spacers front. Moog CC782 coils (+3/4" Heavy lift) Rough Country HD steering and track bar. RuffStuff "The Cure". New control arms. Spicer ball joints. Axle shaft seals replaced. U-joints replaced. Painted front axle. Oil pan gasket replaced. 1-3/4" rear wheel spacers. Upgraded to full compliment gauge cluster. Installed novelty multi-tone air horn. New front brake calipers. New sway bar end links. (2001 Ford Truck) Replaced wiper bushings & upgraded to 97+ wiper arms. Export-only amber turn signals. Replaced DS door glass. Repaired courtesy lamps and added foot well lamps. Installed OEM engine compartment lamp with gravity switch. Replaced water pump. Repaired parking brake (Still needs rebuild, but pawl spring tightened to compensate). Repaired non-functioning tailgate latch. Replaced trim panels on side of cab with ones that didn't have holes drilled in them. New fancy door panels. Installed OEM front skid plate. Replaced exhaust with muffler-back pipe I had from my donor. Replaced missing prop-valve connecting arm to axle. Cleaned and replaced more little sensors and connectors than I care to count. Current Photo: Link to comment Share on other sites More sharing options...
jeeppapa Posted August 10, 2017 Share Posted August 10, 2017 I like it, but I really want to know what kind of deal you got on it. Was it the DDD the drop dead deal of the day? You got me going with your description of how it dropped rite in your lap. Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
8valvehero Posted August 10, 2017 Author Share Posted August 10, 2017 $800- Seller named the price. There are some things you just can't say "no" to. :D That's not like she didn't come with a host of issues: Both doors were totally effed. Few (if any) accessories worked. Rusted-out exhaust. Toasted bushings and ball joints. Tired leaf springs. Water in the floors. Smashed windows. Seized brake caliper. Tailgate stuck closed. Rusted-through fuel tank with slow leak. It seems that the PO knew that the truck was some kind of gem, but wasn't in a position to do the volume of work necessary to bring her back. I'm a known local Comanche aficionado, so he sought me out at work. FATE! The keychain that it came with is awesome: Redneck yard: Link to comment Share on other sites More sharing options...
Minuit Posted August 11, 2017 Share Posted August 11, 2017 That's the deal of a lifetime for a '91 4x4 with a D44, rusty or not. It's even all one color! I've been looking for an underhood light for mine off and on. If you get a chance can you get a pic of what the connector looks like? I thought I had found a light but it turns out the connector was cut off of it. And of course the one listing I found for one doesn't show the connector. Link to comment Share on other sites More sharing options...
8valvehero Posted August 11, 2017 Author Share Posted August 11, 2017 I've been looking for an underhood light for mine off and on. If you get a chance can you get a pic of what the connector looks like? I thought I had found a light but it turns out the connector was cut off of it. And of course the one listing I found for one doesn't show the connector. I spent years accumulating everything I needed to make this look like it belongs there. It's one of those sweet factory options that you hardly ever find-- like the cargo light. The underside of the hood had little detents in it to mark the place to drill. I found my connector neatly tucked behind the factory loom and taped in place. The tape had to be cut for me to pull it up in to position. I had not seen this light installed in-person, and was surprised at the placement when I saw it in the JY. Harness: Placement: I too acquired mine with a cut-off connector. I refused to splice it in and had a bear of time finding that final piece. I've got a hacked-up one you can have for free: Link to comment Share on other sites More sharing options...
Minuit Posted August 20, 2017 Share Posted August 20, 2017 Thanks for the info. I looked at a pair of 93s today and they had a different setup from what the 91s have. In what I guess must have been cost cutting the 93 harnesses didn't have the connector on the engine harness, it just went straight to the light. 1990 and earlier had that retractable thing that always breaks, and a different connector, so I guess this is another subtle MY91 specific thing, and the parts book seems to agree. The '93 harnesses (and I guess the later ones) looked just like the cut one in your pic, but the lights themselves looked exactly like what you have on your truck. I can't find anything on that connector either, or I'd just make my own harness. It looks tantalizingly close to some common connectors but it's probably some obscure French thing Jeep bought a truckload of at one point and was never seen again. Naturally there's no markings of any kind on it. Gotta love having a 1991. 80% Chrysler, 10% Renix, and 10% all its own :fs1: Link to comment Share on other sites More sharing options...
8valvehero Posted September 19, 2017 Author Share Posted September 19, 2017 UPDATE Just dropped a boatload of money (for me, anyway - over $1500) to finish the suspension / steering upgrade. I already upgraded the leaf pack and replaced the bushings. To beef up hauling capacity even more (camper, soil, junk), I bought load-leveling airbags to supplement the MT leaves. 4 Spicer ball joints, 4 new control arms w/ bushings and hardware, HD track bar & bracket, HD Tie rod and drag link, RuffStuff "The Cure", ZJ sway bar w/ end links, Fox shocks and steering damper, u-joints and all new hardware front and rear. I did not replace the front coils. The mileage of this vehicle is relatively low and it's just not in the budget. The will be cleaned and painted. The plan is to pull the front axle, clean and inspect, then install the ball joints and repaint it all satin black. I will clean the underside of the motor and replace the pan seal while I'm at it. I think every bushing and ball joint was 100% beat. Cold, wet winters and hot, dry summers will do that I guess! This brings up the point that engine and trans mounts are also needed. Current status: (love those amber turn signals!) Link to comment Share on other sites More sharing options...
8valvehero Posted October 27, 2017 Author Share Posted October 27, 2017 Been busy! I finished the work started in my above post and installed new axle shaft seals in the D30. (edit- still waiting for my Fox stuff to arrive) I decided to put in coils and went with Moog CC782 for carrying the camper. I'll take the stiff ride for now. I added 2mm of caster shims to offset the almost 3" lift (+1/2" from coils + 2" from spacers). Combined with a Ruff Stuff Cure and she drives like a race car! Sway bar end links from 2001 Ford full size truck. Omix-Ada 18280. While I was under there replacing the oil pan gasket I also scraped tons of crud off all surfaces. Still so much more to do! 👍 Link to comment Share on other sites More sharing options...
8valvehero Posted October 28, 2017 Author Share Posted October 28, 2017 Installed 1.25" wheel spacers in the rear to correct the factory stance. She's sitting pretty, but I may end up lowering the front 1/2". Link to comment Share on other sites More sharing options...
Minuit Posted October 28, 2017 Share Posted October 28, 2017 Your truck is really coming together! Stance of it looks great. Don't mean to hijack but I finally found an intact underhood light. Thanks for the info Link to comment Share on other sites More sharing options...
HOrnbrod Posted October 28, 2017 Share Posted October 28, 2017 45 minutes ago, Minuit said: Your truck is really coming together! Stance of it looks great. Don't mean to hijack but I finally found an intact underhood light. Thanks for the info Where's the switch? Link to comment Share on other sites More sharing options...
8valvehero Posted October 28, 2017 Author Share Posted October 28, 2017 18 minutes ago, HOrnbrod said: Where's the switch? Gravity switch Link to comment Share on other sites More sharing options...
HOrnbrod Posted October 28, 2017 Share Posted October 28, 2017 I know there supposed to be a mercury switch, but where? In the light housing or the connector? I've forgotten........ Link to comment Share on other sites More sharing options...
8valvehero Posted October 28, 2017 Author Share Posted October 28, 2017 In the light housing. Comes on when the hood is 15% open or so. You have to disconnect it if you plan on leaving the hood open though... Link to comment Share on other sites More sharing options...
HOrnbrod Posted October 28, 2017 Share Posted October 28, 2017 Thanks - I'll check it out. Sorry for the hijack - your truck is looking real good. Looks like you got about 3" of lift from the new front coils? They should settle down a bit over time. Link to comment Share on other sites More sharing options...
8valvehero Posted October 29, 2017 Author Share Posted October 29, 2017 The coils gave me about 3/4" over stock 4wd height. I've got 2" (more like 1-3/4") spacers on the coils. After a week of settling, she's level front/rear, but I think Jeeps look better with an extra 1/2" in the rear. I'll see how much more settling occurs. Link to comment Share on other sites More sharing options...
HOrnbrod Posted October 29, 2017 Share Posted October 29, 2017 35 minutes ago, 8valvehero said: The coils gave me about 3/4" over stock 4wd height. I've got 2" (more like 1-3/4") spacers on the coils. After a week of settling, she's level front/rear, but I think Jeeps look better with an extra 1/2" in the rear. Me too. You could always throw a big old thick steel aftermarket front bumper on and drop down a bit more, but I like the chrome bumper that's there now better. I think those coils will settle a bit more. Link to comment Share on other sites More sharing options...
8valvehero Posted November 13, 2017 Author Share Posted November 13, 2017 Link to comment Share on other sites More sharing options...
HOrnbrod Posted November 13, 2017 Share Posted November 13, 2017 Great pic. What a nice setting for your MJ. What is the building used for? Link to comment Share on other sites More sharing options...
8valvehero Posted November 13, 2017 Author Share Posted November 13, 2017 11 hours ago, HOrnbrod said: Great pic. What a nice setting for your MJ. What is the building used for? My father-in-law just bought the place next door to us and this building is on the property. 50 years ago it was a hay barn, now it's a wood shop. Link to comment Share on other sites More sharing options...
Jackrabbit41 Posted November 14, 2017 Share Posted November 14, 2017 Dang bro another one! Awesome Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
Jackrabbit41 Posted November 14, 2017 Share Posted November 14, 2017 Didn’t know you worked at baker Sent from my iPhone using Tapatalk Link to comment Share on other sites More sharing options...
8valvehero Posted November 20, 2017 Author Share Posted November 20, 2017 On 11/14/2017 at 12:03 PM, Jackrabbit41 said: Didn’t know you worked at baker Yep! This is my 4th year. Comanche Club members can give me a shout to receive friends pricing on a day pass at Mt Baker Ski Area. Link to comment Share on other sites More sharing options...
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