Wounded_Fighter Posted July 2, 2018 Share Posted July 2, 2018 Decided to start Documenting things I've been doing to her. First image from purchase. Her current looks. Thus far, Date of purchase 6/4/18 Mileage at purchase: 110,055 Current mileage: 138,xxx 03/25/22 Registry 1 recorded accident. 2/25/2020 6/9/18 Reveal hidden contents Coolant Flushed and changed out. Replaced the fuel pump seal and lock ring (Spectra Part Number: LO01 ) $2.99. Unfortunately I broke the pin off the potentiometer in the process, no more fuel gauge. C101 eliminated, soldered connections and shrink wrapped. 6/10/18 Reveal hidden contents Fuel pump replaced with (Delphi Part Number: CHP10147) $71.99. It was a little bit of a tight fit, I think it was the incorrect part for the year model but I made it work. Side note, this model is reverse polarized... Full is Empty, Empty is Full... 6/13/18 Reveal hidden contents Changed out the fuel pressure sender (Duralast Part Number: PS133) $19.99. 6/14/18 Reveal hidden contents First Oil Change, had my local dodge dealership do it for me this time. 6/15/18 Reveal hidden contents Started replacing fuses since I found one broken... a lot of the fuses were TRASH. Like magic my blower motor started working again! 6/18/18 Reveal hidden contents Had a shop weld the new muffler that came with my purchase of the vehicle ( BONUS! ) Found out quickly that I was basing my shift points on muffler sound! I didnt know what to do for the first 5 minutes... lol 6/23/18 Reveal hidden contents Replaced the Fuel Filter (Duralast Part Number: FF676DL) $12.99. Replaced the Fuel Line leading from the tank to filter. 7/1/18 Reveal hidden contents Modified Valve Cover flutes according to Cruisers tips Replaced Valve Cover gasket (Fel-Pro Part Number: VS50522T) $41.99. Sanded, VHT etching primer, VHT Grabber Green. Coated according to instructions on can. While reinstalling the valve cover i managed to snap one of the bolts in half. Luckily it came right back out without any issues, didn't need to use the drill at all. got a new grade 5 11mm 1/4 20 1inch bolt and washer. The passenger side of the valve cover torqued to spec much easier then the bolts on the driver side did. I'm guessing its time to replace the bolts all together or do something to the threads on the cylinder head? Rerouted the harness along the fuel rail. Didn't like how the harness was routed along side of the valve cover... Scraped some of my 'perfect paint job putting the stupid standoffs back on the valve cover bolts. I plan to rig a stand off along the fuel rail similar to how it was on the bolts, but attached to the fuel rail. 7/4/18 Reveal hidden contents Injectors replaced $50 Ebay Original - P/N 92TF-AA 0280150931 New - P/N BD6-05-034 0280155746 Old New 7/8/18 Reveal hidden contents Pulled the seat, ripped out the carpet. The rust was minimal, but it existed and must die. Sanded and primed, put seat back in. Spot welded filler for a few pin holes, going to JBweld it in the rest of the way to make it pretty later. Interior Phase 1 complete. Passenger side. Driver side Passenger side primed. Driver side primed 7/11/18 Reveal hidden contents Engine wouldn't turn over... all I would get was a click when the key was turned over. And power would short out for 5-10 minutes. Starter was bound up. Replaced battery, Nothing.. Replaced starter. I went with the Reman one. Same warrenty as new, so screw it go cheaper! Part Numbers (Optima Red Top Part Number: 34-78) ; $237.99 +$18 Core. (Reman Duralast Part Number: 16848) ; $73.99 +$40 Core. (New Duralast Part Number: DLG16848) ; $91.99 +$40 Core. 7/28/18-7/29/18 Reveal hidden contents Started to notice the rust peeking through my newly sanded and painted floor. That stuff is aggressive as hell, ate through etching primer. So this time I hit discount auto for some POR-15 at the hefty price of 60$ a quart. Damn. Looks nice applied and dried! Few spots I'm not 100% happy with because I went and applied the POR-15 a little too generously, it apparently bubbles and/or grows when it puddles in some spots. don't know if I should top coat it or not... Installed a new brake switch [W/o Cruise Control], the old plug was melted so I wired some Q/D clips that fit the switch with some shrink wrap over them. (Duralast [W/o Cruise Control] Part Number: F4821) $5.95 (Duralast [W/ Cruise Control] Part Number: F4834) $11.95 Tore the wheel apart a little bit, found the horn wires just flopping around inside, the one wire needed a new Q/D. I can honk at idiots again! Changed speedometer cable. (Pioneer Part Number: CA-3068) $33.99 Deleted a few PO dead end spliced in wires. Cleaned up the plastics a bit with some Rust-oleum WipeNew, side note for this stuff do it outside and do not breathe it in. Good god... Not able to do top coat on the por15 like I wanted to as of yet... for now I'll drive her with floors like this. But I kinda like it. Passenger side Driver side 8/1/2018 Reveal hidden contents Alternator died, drained the battery out... trickle charged the battery for a few days while my new alt was on order. Replaced Alternator. slightly a pain in the a$$ to line up the holes.... The old one felt like it had a loose/broken bearing inside it, wiggle room, knock noise internally. (Duralast Gold Part Number: DLG1370-6-11) $113.99 +$40 Core. 8/2/2018 Reveal hidden contents Fixed my blower motor again. Traced all the wiring and discovered more cr@p PO wire splicing that literally fell apart on a speed bump one day. Respiced, soldered and shrink wrapped. Works again. 8/9/2018 Reveal hidden contents Converted oil adapter to SAE Oil changed. Both done at dealership. (Mopar Part Number: 53007563AB) $10 8/22/2018 Reveal hidden contents Replaced starter relay. Rockauto only part. (Airtex/wells SR123) $23.79 Hornbrod linked a mopar part. Will buy when this one dies 8/28/2018 Reveal hidden contents No Start symptoms again. In the end it turned out to be an "Arcing Short" on the ground terminal which may have been melting the innards of the starters?! Replaced the Starter twice on this day, the first brand new one was bad out of the box. I wouldn't leave the store anymore without them bench testing them... But I didn't get it fixed until I had a second set of eyes, one of my co-workers hovering over the car while I was playing with it, when he saw it "Spark" at the ground terminal when I turned the key. Tightened the DOGPISS out of it, waited 15 seconds, and IT STARTED! Moral of the day, If you can, have parts tested before you leave the store! also, Who gives a damn how sure you are of your grounding points, CHECK THEM AGAIN. Replaced battery (again) Replaced starter. (again) Replaced starter relay (again) Part Numbers (Optima Red Top Part Number: 34-78) ; $237.99 +$18 Core. (New Duralast Part Number: DLG16848) ; $91.99 +$40 Core. 9/7/2018 Reveal hidden contents Jeep choked itself out a few days ago. Got some throttle body cleaner at autozone and a gasket. Disassembled throttle body, calmed and reassembled. It was black as heck, coated it gunk. Runs fine again ( Mahle Part Number: G31510 ) ; $4.59 9/8/2018 Reveal hidden contents Upgraded Battery/Charging system cables! Mean Lemons Upgraded Battery Cables Relocated the Cab to Motor ground for pure difficulty of removal initially, I just didn't have a socket that fit properly in that small space and started damaging the cab. Relocated the Motor to Negitive battery terminal since it was in the incorrect location to begin with, Couldn't remove the bolt for the stock location, nut and bolt are turning in-sync going to destroy the grounds that were located there... so it's attached to the coolant bracket, instead of the dip stick ground. Just need to Locate where I want the Neg to Bat cable... 4wd front end conversion! 10/14/18 to current. Reveal hidden contents 10/14/18 Picked up a 98 cherokee dana 30 front axle to replace the 2wd front. 10/17/18 Popped to cover, gears are good fluid was in decent shape, replaced with approx 1.5qt 75w140, resealed with red RVT. Gear ratio 3.55:1 Did not think to take a picture inside the pumpkin, oh well, its sealed now, if the sides leak 10/20/18-10/21/18 Axle swapped. Swaybar not installed Steering Damper replaced (Gabriel 14040) upper control arms not installed (yet) New brake lines installed, old ones broke and wouldn't come loose, had to create a union joint near tire. Discovered a lower radiator hose leak, replaced hose, and fluid. Steering will need small adjustments still, steering wheel isn't straight at the moment. It rolls down the road, not concerened. Bump stops rub on coils when cornering and hitting a bump... Axle has moved forward 1-2 inches...? Got late, didn't take finish photo yet. 11/10/18 So not installing the upper control arms was a bad idea, there was a ton of caster angle tilt, top forward, which caused the strangle bend in the struts that I couldn't figure out. I thought the bend was just the axle being more forward mounted then the 2wd straight axle. So pressed my bushings in for the uppers, broke out a ratchet strap to bring the axle top forward back so the arms would line up properly... bolted them on fixed caster angle, fixed wheel alignment inside the wheel wells, fixed strut springs being weird... no more rubbing on bump stops no more rubbing on the axle housing... (oops) Upper control arm bushings replaced. FB854 Upper control arms mounted. Caster angle fixed! (Oops) Ratchet strap is on passenger upper control arm mounting point and transmission crossmember. Other point I used to get caster angle fixed was the steering linkage seen below with the 3ton jack. 11/7/18 Reveal hidden contents Ran a new wire for the aux fan since the switch/main line caught fire... 11/19/18 Reveal hidden contents Got A/C Working again! (rewired) entirely useful with winter coming up, I know... Yet still, I did it. 11/21/18 Reveal hidden contents Deleted charcoal canister and lines. Routed fuel vent line into air intake. 12/31/18 Reveal hidden contents Replaced T.R.E. steering gearbox. Autozone TRW p/n JTE7001 $32.99 1/3/19 Reveal hidden contents Replaced 6 spark plugs Discount auto, Champion 344 RC9YC .035 gap $2.99ea 1/13/19 Reveal hidden contents Inspection weekend! Wheres the tap/knock coming from? Jacked her up once again, Dropped the Oil pan, disconnect electrical, turn the crank, inspected each cylinder for skirt slapping... Nothing wrong on the bottom end. Sanded, Primed (SP148), Painted (SP154), Clear coated (SP145) the pan. all VHT 550F rated. Color Grabber Green, . Replaced Oil pan gasket Replaced Oil pump Replaced Oil Filter 3/4" 16 thread (yes we changed from metric remember?) Replaced Oil 5w30 Replaced Transmission oil. 75w90 (Melling Oil Pump Part Number: M-167HVS ) ; $96.99 (FEL-PRO Oil Pan Gasket Part Number: OS34308R) ; $26.99 Out with the old, in with the new again My little rule going into play again. It comes off, It goes Green. 2/5/19 Reveal hidden contents EGR delete. Removed all of it. Got a block off plate on ebay, 15$... easypeasy. 2/6/19 Reveal hidden contents Changed out the pillar lights. Had to splice into the original harness to adapt to the new light housing. Same style light, just different connection and slightly larger. Had to cut maybe 1/2 inch out of pillar length wise of the light. Also go green led bulbs for it Light harness wiring, red hot, black with trace is door switch ground, black is ground for light toggle. 2/7/19 Reveal hidden contents Dealership oil change & inspections completed. 3/18/19 Reveal hidden contents Replaced serpentine belt Degreased/washed engine bay. (Continental Part Number: 4060852) ; $36.49 3/20/19 Reveal hidden contents Replaced idler pulley (Duralast pulley Part Number: 231097) ; $24.49 5/6/19 Reveal hidden contents Got my meanlemons bored throttlebody Original bore 2.0480 New bore 2.3600 5/13/19 Reveal hidden contents Replaced air intake filter. 5/17/19 Reveal hidden contents Replaced dash gauge cluster Gained tachometer! Also new color layout. Gutted it and cleaned it, matched speedometer mileage with old unit. 5/18/19 Reveal hidden contents Replaced harmonic balancer. [Torqued bolt to 60ft/lbs] Rubber between it was surely stepping out (Dorman Harmonic Balancer: Part Number: 594-018 $44.99) Adjusted idle air bleed screw on the new .040 over throttle body, idle between 700-1000rpm now. We'll see what highway does to it now. 6/3/19 Reveal hidden contents Oil changed at dealership. 7/6/19 Reveal hidden contents Jeep overheated on a drive home, in the rain... So.. investigation time. Drained system, Pulled some hoses off, flushed heater core. No hard chunks, however... it flooded the floorboard..... Replaced hoses and bypassed heater, oh joy... Filled up and tested, Still overheated. E-fan didn't kick over. Replaced radiator switch, Autozone SW594 Still didn't kick... still overheated Temporarily ran a flip switch to manually kick fan... Looks like it's time to do a closed to open conversation. New pump new radiator.. soon to come... 8/23/19 Reveal hidden contents Oil change at dealership And yeah I had been neglecting doing this so I finally did it... scold me. Rear diff fluid changed. Fluid didnt seem bad, no metal chunks, just smelt bad so yeah it was change time. Also discovered my fuel pump wire harness was rubbing on my drive shaft... good thing I check everything so diligently. Fixed with some electrical tape and zip ties. Also my fuel line was cracking again. Got new thicker line... 10/4/19 - finished 10/14/19 Pulled the head! Complete at 126,150 miles. Reveal hidden contents Many people said I shouldn't and people thought I should. To be honest, I'm glad i did. There has been so many bolts either loose or broken off in just the head alone!! 4 loose exhaust/intake bolts, 1 broken exhaust bolt (yeah cylinder #6 in the back...) 3 cracked exhaust pipes, head gasket was split in the rear (no cross contamination with fluids though! Lucky..) all head bolts except two had fluid on them possibly oil, the other 2... well they we're exhaust/head cross contamination bolts, dry/rust, just bad. Wrapped the headers Pulled the head Brown dog Industries motor mounts installed, passenger side was a little bit of a challenge. New water pump, thermostat housing, thermostat, lifters, head gasket, head studs, head. Check. Done. Had the valve cover powder coated. Had to gut it. Luckily.... I found 2 lots that had the PC valves on top in them!! And a new oil cap! Perfect fit! Replaced head gasket - fel-pro perma-torque gasket p/n 530sd Replaced head bolts with arp head studs - ARP p/n 146-4201 Replaced lifters - melling JB-2011 autozone Replaced water pump - high flow 4wd.com Replaced water pump gasket- fel-pro Replaced thermostat housing - high flow 4wd.com Replaced thermostat - 180 Replaced thermostat gasket - fel-pro Replaced exhaust header - Pacesetter (wrapped also) Replaced intake/exhaust hardware - grade 8 Replaced fuel injector orings - yup Replaced motor mounts - Brown Dog Industries Coolant flushed Oil changed 10/18/19 Reveal hidden contents Fuse panel was looking bad. Hell, it was wiggling in its location. Replaced all of the fuse holder pins (ATO connectors) Replaced panel holding hardware Sealed panel to firewall with sealant. 11/14/19 Reveal hidden contents Replaced radiator! Went with the mishimoto radiator replacement since my unit decided to rupture. Fitment was easy on my Jeep. No real problematic complications, even with a/c. Still haven't switched to the newer overflow bottle... Mishimoto radiator - $331.36 Omix-Ada radiator upper isolator - 6.96(ea) 2/15/20 Reveal hidden contents Balanced the tires. Rides a little nicer. The Accident... 2/25/20 Reveal hidden contents 2/25/20 Reveal hidden contents The Crash. 3/7/20 Reveal hidden contents Fenders off. 3/15/20 Reveal hidden contents Removed wires for accessory lights Removed some components for axle removal Discovered more damage. - Driver side upper control arm split in half and shot into the frame. 3/22/20 Reveal hidden contents Picked up the sacrificial lamb. XJ 3/25/20 Reveal hidden contents Front bumper is off... put up a fight on passenger side... 3/29/20 Reveal hidden contents Fluids drained out last night. Radiator removed. Condenser is off to the side. Alternator removed. Oil pan removed. Harmonic balancer removed. Timing cover removed. Timing gearset replaced! (Finally... had it sitting on a shelf...) On todo list Oil pan gasket replacement (again) Timing gasket replacement Timing cover balancer seal Alternator replacement (again) Notes.... Pan is damaged. Going with a new(er) one. The new oil pump doesn't seem hurt so its gonna stay. Alternator has a squeak in the bearing. PAINT?! oil pan Timing cover Alternator bracket. 4/2/20 Reveal hidden contents Interior upgrade... yeah going to just include these into the fix since it's being done at the same time. Door cards! The ones that came with the cherokee had some carpet on them... so I just took what I wanted off the card and drilled / cut them into my existing cards. Before After 4/28/20 Reveal hidden contents Removed axle from the donor vehicle and moved it in front of the MJ... She needs some new bushings and stuff... won't be installed yet. 4/30/20 Reveal hidden contents Some stuff back from my paint guy! Black & Clear coat Fender to frame brackets Upper radiator support Radiator support to front clip support Fender to front clip support Coolant overflow shelf Alternator to engine bracket Alternator to timing cover bracket A/C compressor bracket ( fun note paint interferes with mounting the compressor ) Green & Clear coat Timing cover Radiator to Battery hold down bracket Waiting on... Drip pan (green) Water pump pulley (green) Radiator support hood retainer bracket (green) Drip pan rear seal bracket (black) Nice to have some progress 😎 5/1/20 Reveal hidden contents Paint and new stuff. Found out that NAPA has a decent selection of old jeep body hardware. Got a bunch of new screws, nuts, and speed fasteners to go with some of my powder coated parts and my soon to be painted parts. Going to be going back for the little black square pieces that go inside the front grill... don't know what hardware went in there... Started some prep and painting. Got the cleanup and primer down on the new fenders (exterior side) need to still prime the inside of fenders. Apparently the donor/parts jeep I purchased had a set of new plug wires chilling in the trunk! Guess the MJ got a new set of wires! Replaced spark plug wires! $0.00! 5/19/20 Reveal hidden contents Cut the old damaged MJ Inner fender wells OUT! Dropped the exhaust collector pipe since it was damaged. New one came in the mail a few days ago! Discovered the Knock sensor was split in half... removed it. Still finishing up removal of inner wells spot welds before adding in the new wells. 05/22/20 Reveal hidden contents Finished cutting the remaining pieces of the inner fender structure. 5/24/20 Reveal hidden contents Replaced oil pan gasket Replaced oil pan (sad fact. And it must have been warped a little... it was a BEAR to install) Reinstalled water pump pulley 5/30/20 Reveal hidden contents Got the exhaust collector pipe replaced. Also got the replacement pass side inner fender structure cleaned up. Started on the driver side an exploded the spot weld cutter bit... Reinstalled the accessories belt. Added 6qt 10w30 rotella synthetic blend. Once complete she will have a trial run and a fluid flush for new fluids again. Only doing this for the length of time she has been sitting... 6/6/20 Reveal hidden contents Found a leak after adding new oil. Dropped the pan again, turns out the lip on pan seal got crushed. Sweet. Decided to just knock out the RMS which has had a small leak before while I'm at it. Replaced oil pan seal OS34308R felpro o'reilly's Replaced rear main seal BS40612 felpro o'reilly's 8/7-10/2020 Reveal hidden contents passenger side lower control arm frame mount was damaged in the crash. Got it swapped out with a junkyard part Axle installed Ordered new steering components (rustys offset 1ton) Ordered new cooling system (mishimoto 3fan) Ordered new trackbar (rustys) Scheduled glass replacement. Had a HELL of a time with the impact tire. Didn't know the rim was damaged too.. Long story short... new tire, new rim. Ripped the interior trim out and headliner for glass installation. don't want them bonding together... 8/15/2020 Reveal hidden contents New glass in 8/19/2020 Reveal hidden contents Trackbar, Stabilizer and drag link have arrived Installed Test drive.... deathwobble... wobble tore a hole in my new collector pipe... F*** 8/20/2020 Reveal hidden contents Cooling system arrived Doesn't seem to fit properly...? Makes contact with steering gearbox. To be Continued... 8/21/2020 Reveal hidden contents Alignment shop trip Somehow lost 2 bolts for my waterpump pulley and one of the Coolant hose clamps were loose as a goose. Checking torques on everything pretty much now... 8/21/2020 Reveal hidden contents She's BACK on the road! 8/29/2020 Reveal hidden contents Replaced distributor, apparently the timing was like 1/2 an inch past TDC SPECTRA PREMIUM CH09 (rockauto) 9/3/2020 Reveal hidden contents Replaced ICM Replaced ignition coil So I decided to drain and fill the old BA10/5. Slightly burnt oil (Go figure with how I drive it...) A good amount of sludge And this 1-2inch metal pin? Attached to the magnet... So I drained it out (clearly) searched inside drain hole with a magnet for potentially more pieces. Nothing extra came out. Fed her what might be her last meal... So I gave her something special (Royal Purple 75w90) 10/20/20 New K-Suspension 12 hole injectors installed. New K-Suspension cyclone fan system installed. Fan system got... rigged in last min so I can get to work... fix it later... 10/24/20 Precision Replacement Parts (prp) stuff arrived Replacement window/door seals! Got driver side in. Had a big gap in forward corner after install... the triangle window. Still need to do passenger side. 11/30/20 Replaced the headlight switch (suspected bad) 01/??/22 Launched too hard, engine destroyed one of the cyclone system e-fans. She heats up good without the center fan apparently, or maybe the hit damaged the water pump.... 03/25/22 Replace driveshaft u-joints 05/20/22 - 05/30/22 Exhaust/Intake gasket blew out, and she has been overheating on me a little bit, time for some love... Replaced exhaust/intake gasket Replaced fuel regulator Replaced injector orings (head side) Replaced injector #1 (had a cracked body) Replaced Flowkooler hi-flow water pump & gasket Replaced thermostat & gasket Replaced broken e-fan Deleted stock coolant tank Installed newer style coolant tank Used old curved heater tube from old bottle return as a bypass (thermostat housing to water pump) need to block off or repair the heater... Vroooooom! 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