My first Jeep / Picking up the Pieces

[dankicksass]

Hi I'm Dan, I'm from Jersey, and I've always been a car guy. Was a Chevy guy in my teens, then I got heavy into VWs, then I relaxed it and just worked on cars for a while and didn't try to do anything fancy to my own. This is my first Jeep. It's a 91 Comanche 4.0 AT 4WD with a Dana 35 rear. It's not very pretty right now but the bones look good to me. I got it in Pennsylvania where it would not pass state inspection so it sat at the PO's house forever before I saw it. I'm a pro tech but I don't know how to weld yet, guess it's time I do.

The good:
- Clean title
- It runs and drives and can keep up with highway traffic
- It has a little bit of lift and came with plenty of 31s
- It has a full console with beverage holders

The bad:
- Rotted out rockers and bed
- Tailgate handle is missing, tailgate isn't in good condition
- The steering is crap
- The existing lift doesn't look well done and the back end is way too low
- The blower doesn't work and was disassembled by the PO
- The engine does not appear to reach operating temp during normal driving
- The engine is running really rich, probably due to the cooling issue
- Fuel level gauge is crap
- Exhaust leaks
- 4WD doesn't work as well as I'd like it to
- Bunch of missing interior bits
- Stereo doesn't work
- Junkyards around North Jersey haven't been very good for my other vehicles but maybe they'll be good for Jeeps
- Rear bumper doesn't fit and it's rotting out
- Doors are missing limiters, not very good condition doors in general

The plan, in order of importance, I guess:
- Fix the blower and change the T-stat and WP if necessary
- Fix the exhaust bare minimum so it stays out if the cab. New exhaust later
- Fix the tailgate or find a new one
- TJ Rubicon flares, cut out the bed rot, fix the bumper as much as necessary right now
- Remove rocker rot and fix the cab
- Remove carpet, repair floor if necessary, fit new carpet and headliner
- Get the ignition cylinder replaced before it leaves me stranded
- Fix the lift and steering. SOA conversion probably. New springs definitely. Like to get a better axle in there
- Dye interior black, recover dash top with vinyl, install nicer seats, probably MkV Jetta vinyl
- Need to get a new fuel tank because the anti-slosh is crap. Doesn't leak right now but it's on its way out
- New wheels and tires. Highly likely it'll be JK 17s with 2in spacers and 33s unless somebody can talk me out of it
- Transfer case has angered Jobu, so it will need attention. Would like the later Cherokee full time switchable box if that's not crap. I'm sure someone will let me know.
- Doors need attention, like to update them to late model with power windows, locks and mirrors
- Late model front end update and a new rear bumper with late model endcaps
- New paint, probably white
- Stereo fixed sometime in there
- Somewhere in there I'd like to fit a Chevy V8 and new trans in
- Also if a rollbar finds its way into my lap I wouldn't turn it down
- Needs LED lighting everywhere

 

[dankicksass]

I didn't have a lot of time to work on the Jeep today. I wanted to try to fix the tailgate but it came to my attention that the tail lights are crap. One was out so I went to do the bulb, but I was damn near horrified to find house wire nuts used by the PO to repair existing wiring.

So that's got to go. Fortunately I have a brand new pair of wiring harnesses from a late model Silverado that I got for nothing. They have two brake/turn bulbs and one reverse, all 3047. I was saving these for my Monte Carlo, but it has perfectly good lighting and I need these now. New from the dealer these harnesses are about $40 if you were to buy two of the cheap side 25906854.

I know what you're thinking. "Dan, those bulbs won't fit." And you're right. This required minor modification of the bulb receptacles in each lamp. 90 seconds with a Dremel tool and they fit. About 1/8in needed to be taken out of one tab slot for each bulb and the ground wires needed to be extended between the bulbs. I think older GM harnesses with the reverse on bottom would probably require less wire modification, but these were free to me. I chose to modify the plastic lamp to fit because it's much easier this way than modifying the bulb sockets. I think the stock bulb sockets would still engage, but it doesn't really matter. I have no intention of selling these lamps. If I ever buy new lamps, I'll just modify those again. The trimmed areas are marked in white.

So far this has worked brilliantly. I've now got three bulbs per tail lamp and I need to join four wires per side. Total cost: about $0.50 worth of solder, heat shrink and tape, and ten minutes. Not so fast though. These lamps have been thru the last 23 years and it shows. All the mounting tabs are cracked or broken.

So tomorrow I'll be going to the store for some supplies. I'll split the lamps, reinforce the mounting tabs by plastic welding some metal lock washers and replacement plastic in. The lens has a bit of cracking, so that will be addressed. Tomorrow is another day.

 

[87manche]

make sure that ground there is in fantastic shape. The fuel pump and level sender ground through it.

 

[yexi25]

Good post. :rof:

 

[dankicksass]

I fixed my tailgate today. When I bought my Jeep, the tailgate handle was rotted off and I had originally intended to rebuild the handle with new bushings on the functional assembly and fabricate my own release handle with a sheet metal brake. I just hadn't made it a priority.

So I was at the parts store the other day to pick up CV axles for one of my VWs, and I decided to take the broken Jeep handle with me so I could compare it to their aftermarket handles. Turns out a 88-98 Chevy C/K tailgate handle is about the same size, but the bolt pattern is different and the rods connect at the bottom instead of the top. I decided that was good enough for me, so I took it home. Dorman 77077 - $21 with tax.

This component is a really easy install. I had to trim away a little metal inside the tailgate handle hole to fit the new tailgate handle through, but other than that it's just three holes drilled and done. The whole project was about 20 minutes. I'm happy with it so far.

 

[dankicksass]

I haven't posted an update in a while. I recently got new wheels and tires, refinished those wheels, and de-chromed my badges.

But this weekend's project is a little more extensive: all new suspension.

My Jeep came with 4.5in lift coils and no other lift components installed. It was a little unpleasant. I decided to get rid of almost everything and start fresh. The only thing I kept were the leaf springs; they're not broken and I'm not ready to bob the bed yet but when I do, I'll replace them.

In the front, Upcountry coils and Energy Suspension spacers should net me about 2.5in over stock height up front. Daystar TJ bump stops will keep it in line. WJ lower arms and XJ upper arms with new upper bushings on the axle will keep the front planted with a new track bar. Extended sway bar links will prevent rubbing. The old ones rubbed on my coils all the time. Monroe extended shocks should smooth out the bumps.

Out back, the leaf springs get augmented with a Superlift add-a-leaf, 7in adjustable shackles and Daystar poly bushings. Monroe coil-overs should make it nicer to actually use the bed. New stock bump stops and parking brake cables for safety. My Jeep didn't have any when I got it. Extended brake lines all around and that's everything.

 

[devildog0]

Good start man. Good to see an MJ getting saved from the scrapyard. I love those things but there's not enough of them left out there

 

[dankicksass]

Good start man. Good to see an MJ getting saved from the scrapyard. I love those things but there's not enough of them left out there

Thanks dd. I don't see a lot of these around. One of my buddies has one too, but it's a mud truck.

 

[devildog0]

Back "in the day" when I was still in high school I almost bought one for 1800 bucks. My dad talked me out of it. I wish I would have grabbed it . My next favorite Jeep to the XJ

 

[jbain08]

Nice find.... for offroading I like a AT much better than an MT and the fact that you found a HO AT truck is pretty cool. I bought a 88 and spent months swapping it over to a HO AT Truck. Keep up the good work.

 

[CompleteCherokee]

looks like a good start to a cool project.