Need Comanche Project Advise

[dotnetrob]

Bought my 1989 Jeep Comanche Pioneer 4x4 Auto with 4.0L with 189k on it 2 months ago today.  Had looked at multiple comanches trying to find one to repair/restore, choose what I thought was the best of my options at the time.  Now I am wondering if I made a horrible mistake.  Have no real life friends so I have no one to slap me the back of the head and tell me I am an idiot.  Looking for some advise on if I should keep pushing ahead or admit I made a mistake and its time to take old yeller out back.   

 

I know this comanche had alot of rust, body and part of the cab floor need alot of repairs.  Frame was pretty rusty but couldn't find any holes on this one, others had holes in the frame or other damage, so was hoping to clean it up the frame.   Engine runs good even has working A/C, and besides the No Start Issue that turned out to be the fuel pump coming disconnected inside the tank, when I got it home, the engine seems solid enough.

 

Purchased it and drove it home 500+ miles.  Had no issues except the weak brakes.   Rear brakes had a leak, and the load sensing valve was not working, so failed state inspection and had to have a shop do some repairs to get it approved.  Brakes now work but are still very weak .  

 

While trying to fix the brakes, found the front has not been bleed for years and may not be working well and everything on the axle is rusted shut.  Bleeders snapped off.  Was going to take it all apart, replace the calipers, rotors, etc....   But it keeps getting worse.  The passenger side came apart easy, caliper came off, rotor came right off.  The driver side, caliper came off easy, but rotor was rusted on and the edges of the rotor looked in bad shape, had to beat the rotor off.   The dust cover on both sides is completely rusted apart, passenger dust cover is 1/2 still there, the driver side is all rusted away, only pieces left.   Decided to pull the hubs so I could clean everything up and replace the dust covers... but that is were the fun stopped or started, depends on your perspective.  

 

The hubs are rusted to the axle or at least the knuckle.   On the passenger side, got the axle nut off easy, took off the 3 hub bolts off and the hub will not come off.  The driver side is worse, can't even get the axle nut off, an impact and 4ft breaker bar and it won't move.   And the driver side has the same hub issue, all 3 hub bolts are out and hub is just rusted to the axle/steering knuckles.   

 

Have sprayed alot of pb blaster and used many methods of persuasion,  and I can't get either hubs off.  Guess I can try just taking the knuckle off, with everything still attached... never tried that, not sure it would work.  

 

Now I am questioning if all this work is going to be worth it.  Is the axle going to have even more rust related issues even if I work past the hub/brake issues.   If I go find another axle to swap it out for, am I just putting a good axle on a rusty pos that needs to be taken out back. 

 

Picture is from the day I got it home, back when the brakes were even worse and a picture of the front, you can see the rusted out dust cover.  But its a good shots of the rust. 

[eaglescout526]

Well to start, if you havent dropped your VIN in the registry, it looks like you got yourself a Metric ton package or someone did the swap. Either way the D44 is desirable.

 

Honestly, These Jeeps are prone to rusting out and it just depends on how bad the rust is and how much time you want to put into this. 

 

As far as being an idiot, well purchasing an MJ is far from being one. Now if you bought the most clapped, frame collapsing MJ out there, then yes a smack on the back of the head is warranted as you said. But what I am seeing is just something that had maintenance neglected upon it and was worked like a truck should be. 

 

Honestly, once you have all the hard, neglected work done, youll have a good reliable truck to drive around and a rare one that most folks dont recognize and or see anymore. The rarity alone should be enough to put in the work to make it reliable. 

 

I am sure others will chime in shortly. More pictures of what youre working with, the better we can help ya further. Oh and the best part, everyone on here is willing to help out.

[ghetdjc320]

I agree. Of course, we haven’t seen all the pics yet but so far I’m just seeing a decent bit of surface rust. I’ve worked on similar before. I’d suggest a good undercarriage cleaning first. Get under there with a pressure washer with a good blast nozzle and spend some time cleaning it all. You may find clean metal in some areas underneath caked on mud and scale. Once it’s cleaned up though, take a bunch of pictures of what the underneath looks like  

[89 MJ]

From what I'm seeing, that truck doesn't look bad at all rust wise. As long as the frame is straight and solid, I think the truck is worth fixing (don't confuse this with it being a truck you could make money on if you want to sell it in the future). Like eaglescout526 said, these truck are super prone to rust. Things like floors, rockers, cab corners, and bedside repairs are fairly easy.

 

If you don't have a torch for heating up rusty parts or hardware, get one. It will make your life much easier.

[dotnetrob]

Appreciate all the input, will keep pushing along with the project.  Luck I found this forum with so much great info about Comanches.  

 

Finally got the hubs off, its amazing how much persuasion an 8lb hammer and a Bearing Hub Removal Tool has.  Of course today I learned what a D30 CAD axle is.  Wasn't expecting two short axles shafts when I pulled them.  Going to replace the driver side front axle shaft for now since I can't get the spindle nut off the shaft, passenger one is in good shape.  Picking up the rest of the front in parts tomorrow, but going to clean up the axle before I proceed.

 

On 8/17/2025 at 5:04 PM, eaglescout526 said:

Well to start, if you havent dropped your VIN in the registry, it looks like you got yourself a Metric ton package or someone did the swap. Either way the D44 is desirable.

 

Will drop the VIN in the registry now.   Keep forgetting

 

Adam's Polishes

On 8/17/2025 at 5:22 PM, 89 MJ said:

If you don't have a torch for heating up rusty parts or hardware, get one. It will make your life much easier.

 

Actually have a torch, but haven't used in years, just need to get the tanks refilled.  I am sure it will come in handy soon with this truck.

 

 

 

 

 

[coolwind57]

Dude, you got a Dana 44....  Darn-near a Unicorn even if it's not a factory Metric Ton model.  It took me several years to find a MJ D44 for my truck.  

 

I'm not seeing anything crazy in the two pictures you posted.  I'd love to see several more pics. 

 

From what I see and hear you describe, you got a FUN one to work on.  Baby steps and you'll have a kickin' ride.