Project CRD MJ is born:

[zluster]

Scored a couple of these at the junkyard today, Gentex ZTVHL3. Has 3 homelink garage door openers, auto dim, compass, and outside temp. Uses standard base so it can be added to many different vehicles. I'm still looking for a holy grail, all of the above with courtesy lights.

Pulled an engine/trans/transfer case from a 2000 XJ. Then took the transmission only. Also got a nice front driveshaft for $20.

And then pulled the engine/trans/transfer case from the MJ:

Empty already:

This is what caused the leak, input seal ripped, likely would have been fine with a replaced seal, but I've gotten to the point where I don't trust this transmission and would just rather try another right now.

New used transmission, need to pressure wash tomorrow and then get it hooked up, and hopefully back in and running by the end of the day.

Sad to see it empty!

I'd like to move on, get my driveshaft ordered, get the front end built and installed. And finish up with the seats, I have this seat heater kit waiting to be installed, and I have the electric bases to install. I'm looking forward to some of the more "fun" stuff like getting the interior together. I'm looking forward to having the interior complete and a Jeep I can sit in! (of course, if it doesn't drive it doesn't matter if its sits)

 

[zluster]

Ok, so I pressure washed, swapped things around, and got the engine back in the MJ. No leaks. Engine sounds good. I had a little bit of lifter tick that cleared up pretty quick. Annoying setback to be sure, but that’s done and I can move on.

Video of it running after removing and reinstalling with new trans.
https://youtu.be/z7ifl6oZu9c

Also, I got the parking brake working.

 

[zluster]

Did a 10 minute break in, I'll do some more tomorrow.

Got the aftermarket high idle switch installed, but then I got to thinking about it. It does not have a backlight for the text when the headlight is on. But I realized you can swap the switch cover over to the OEM switch........so I realized I could install it on a spare fog switch.

But then I got to looking, and realized I could also install it on a spare defroster switch......

The high idle works by grounding the ECU pin that tells the ECU to goto high idle. The fog switch, and the aftermarket switch work by providing 12V.....not ground. So you have to use the switch to turn on a relay, which instead of providing a larger 12V power source will provide a ground. This works fine, but its some complication.

However if I use a spare defroster switch and modify it with the new cover to set on instead of toggle.........So I have a defroster switch that simply toggles on, then on the back one of the wires provides ground! Normally when you press the defroster switch down it momentarily provides ground to set the timer relay. By modifying the defroster switch to stay on, NOT as a momentary pushbutton, when it is in the down position the ground is connected, up ground is off, so in effect I have reproduced the stock high idle switch! Pretty pumped about such a small thing, but its the details that get ya.

Switch down, continuity to ground:

Switch up, open circuit:

Moved it to a different spot to be closer to the stock wiring that I will use from the rear wiper.

I had to modify the electric seat base to fit the rear floor of the MJ, the mount closest to the bottom of the frame was too low, and caused the seat to "rock" on the floor, a little bit of hammering and a the bracket fits like a glove. Next up I drill a plate to act as a load disperser on the bottom side. for bolting the seat down.

Its Miller time! Miller moth that is, this is what I came out to when leaving my parents for the night.......and this was without any garage lights on, they come inside seeking warmth at night an congregate where its warmer. Heaven forbid you leave a light on even....

 

[zluster]

So the other night when doing the break in after running it at high RPM I was looking around at the engine for leaks and such, my power steering was spitting a little fluid out as it was bleeding down air and such. So I was looking around that area when I noticed a giant red patch of ATF pooled on the intake manifold! WTF?

So I get to looking around and I realize its not ATF, I was seeing a triangle shaped hole in the casting and behind that was a glowing hot exhaust manifold!

I managed to grab some pics, but it cooled off quick enough that I didn't get to grab a picture as the super red it was right after I stopped my break in run.

Got the hack n tap done last night. I need to measure and get my driveshaft ordered for the rear, hopefully I will get that done tonight.

Going with this length I have 100% engagement of the splines on the transfer case:

So big ticket items remaining:

-Set pinion angle and weld perches(likely get pinion pretty close tonight for purpose of drive shaft length measurement.

-Door latch modifications.

-Drop arm bracket install (need some new hardware and maybe some tweaks to install).

Front end:
-Gear setup.
-WJ Brake setup(weld spacers to knuckles is biggest part of this).
-HD steering setup.
-Track bar bracket and stabilizer
-Track bar(likely need custom length or adjustable)

Body wiring:
Cab interior, need to finish cleanup and strip down of XJ wiring.
Body rear, need to decide how tail lights will be wired and how tail light wiring, fuel pump wiring, and trailer tow harness wiring will exit the MJ and reach the back.

Extra's: Need to run wiring for EXT IDLE, power for heated seats, power for electric seat bases. Need to decide how to control heated seats, I am wondering if its possible to use the XJ heated seat controller with the aftermarket heated elements. Need to research this possibility.

Need to drill hole for antenna to pass into cabin, should have done this before AC box and dash was in.....woops.

Work on interior install, body wiring being sorted is critical path now for the interior install.

Finish AC line install and check AC system for vac.

Finish Rear bumper grinding, decide on paint vs galvanized option.

 

[zluster]

I had to open up the LCA bracket in the drop bracket to get the caster angle adjuster in place. Used a bolt and nut to "press" it apart. Worked pretty well.

Drop brackets installed finally, control arms loosely bolted untill axle is in and I can torque them.

No idea what this barcode was for, the newer jeeps dont have this:

Masked off the vin plate, ready for paint:

Looks so much better with fresh paint:

Got the 20 ton harbor frieght press today:

Rear seat bolts drilled:

Heated seat install:

 

[zluster]

Nice having a large benchtop to work on instead of working on the ground:

Build time and date of seat:

And back together:

Freakin cig burns! Ugj. This is a super nice seat, 45k miles, from an 01, about as new as you can get. The vynil is in good shape, the foam is in great shape, the fabric is really nice(now that its cleaned), and it has the fukkin burn marks. It'll have to do for now untill I can figure out something nicer, but these burns are gonna bother me.

2door seat folding mechanism:

Installed for testing! For the first time in a decade I got to sit in it!

Video showing the seats a bit:
https://www.youtube.com/watch?v=FSTcZc0Utg0

So then I started building a harness to go from the simple overhead light to the console with compass. Had to splice in a plug since I didn't have an intact harness to swap in.

And then tested the mini overhead console from the sunroof ZJ, and it works!

Then I got to messing with this connector under the passenger seat:

I always thought this connector was for power seats, but then it didn't make sense why it was under the passenger but not the driver, especially since the power driver seat was more common than the dual power seats. The dual power seats only seem to have been around in the last few years when heated leather was an option, and even then only on the heated leather seats.

But then I got to comparing the connectors on my OEM heated leather seats and they don't match, so I was wondering what it is. Then I poked around, it has one small wire that is a switched source, and another large wire that is dead. I quickly traced the large wire back to the junction block and verified continuity. After poking around the connector it is C6 at the junction block, and after even more poking it gets power not through a fuse but a circuit breaker!

The vertical circuit breaker closest is CB30, and its for the wipers, the horizontal one furthest away(blurry) is CB28 and its for the window power, and CB29 with the empty spot is for the power seat power! So I just need to rob a wiper circuit breaker from the junkyard and that wiring will have the exact power I need for power seats or heated seats. This also means its super easy to add seat heaters to a jeep with manual seats.

 

[zluster]

Driveshaft delayed untill monday.

Also, fck fck fck fck fck. I have wasted so much time from this. Lost days to this:

https://www.youtube.com/watch?v=6z6JDgUxwj0

 

[zluster]

Today freerider was kind enough to help weld on my perches after I set the pinion angle.

After some delays I got the axle back under the Jeep, sitting at ride height, final torqued, my driveshaft arrived Friday despite getting a notice it would be delayed.

And......... I got the parking brake hooked back up, driveshaft hooked up, seat put back in, and then started it up to move it under its own power! No hydraulic brakes, no steering, no a lot of other stuff. But it moves!

https://youtu.be/fAiKsfz2bP8

 

[zluster]

Checking out the JKS spacer on the new unit bearing:

Got the housing stripped out. New Bushing, but old balljoints.

Nice being able to do this on a bench.

Working on setting up gears, no idea at what point I was at with this and the bent carrier.

When I ran to the junkyard I spotted this MJ, Ive seen him at the junkyards several times over the years, I dont think the last time I saw the jeep he had a 97/98 interior which is what he has now.

Interesting way to plug the vacuum line when the reservoir is gone.

Checking pinion angle:

Checking driveshaft:

Plenty of clearance:

Got one rotor drilled, checking out the WJ big brakes:

Sway bar link interference:

 

[zluster]

Rear end removed for Perch welding by freerider:

Empty again:

Draining gear oil:

Rusted bump stops, had to torch the hell outta them before they would break loose.

Brakes are huge!

Sitting back after perch welding:

The used line is what was on the donor jeep, the brake line is pressed into the fitting, and the bent metal line is all sorts of wrong shapes to run to the T. Someone gave me these new rear lines some years back and luckily they are the perfect thing for what I need to do.

So I drilled two holes, the keeper hole to keep it from spinning, and then the bolt hole which I tapped out to M6. Then I used the KJ stock retaining bracket. Very nice solution, about as easy as it gets.

Now the stock KJ rear softline seems to be long enough if I make it reach the frame right above it. If it turns out to be too short then I will look at some other stock line for an extended rear line. I will either drill and tap, or use a nutsert if the frame is too thin there.

Installed the last of the AC lines and pulled a vacuum, seems to be holding for the few hours I left it on, I will check again tomorrow and if it still holds I will charge the system and test. I really wanted to charge it tonight and try and test the AC system. I would love to know the AC system is working.

 

[zluster]

Ok so no pics, but the AC is working! It held vacuum overnight, then I had to break the vacuum to add oil, then filled with some redtek r12. Its blowing cold and kicking on as it should. The charge of redtek is a little low, before I start driving it on the regular I will add some more, but in case I have to break the seal there is only one can in right now.

Next up I pulled out my new tubing flare tool, The stainless line came in today so I got to making lines. It went pretty well and I got the rear axle lines made up to the T.

Used the factory clip to put some hose around for anti rub like the factory did, then added a couple of more pieces further up for the same purpose:

So tomorrow I will build the last bit of line from the Cherokee rear line which ends by the gas tank, to the rear softline. Also need to mount the softline to the frame.

 

[zluster]

Small progress tonight but still progress. I got the rear flex line mounted to the body, the last bit of brake line fabbed. I got the second WJ caliper drilled on 5x4.5. I got both calipers mounted, YJ brake lines bent to work with WJ calipers. Brake pads installed.

Started putting fluid in the system. Both rear lines at caliper were leaking. Turns out I had them installed backwards so they did not tighten onto the crush washers correctly. I fixed that, had one more leak in the engine bay where the passenger line splits into two pieces near the heater hoses.

And got it bled and working, brake pressure feels good.

So hydraulic brakes work, parking brake works, ac works, heater works.

Still no steering, track bar etc. work in progress.

Doors need to be mounted, or rather mounted so I can get the striker figured out.

Still the cab back wiring modifications needed. Plenty to do, but it’s getting closer.

 

[zluster]

With the help of freerider(thanks again!) I got the WJ steering arms shortened and reinforced after cutting about 4.5” out of the middle. Also got the raised sway bar link brackets welded.

Got everything in And hooked up, rough aligned, and took it for a spin around the circle. It runs, steers and stops! Drivetrain is nearly done.

Making progress!

https://youtu.be/tbqe9X9Zpts

 

[zluster]

Awesome progress, such a great feeling now that its alive I bet!!

Yes it’s very exciting that it’s this far! I have enough little stuff left to sort out that I know it’s going to be plenty of more hard work.

Logistics of getting my plates on it, getting it to the muffler shop, alignment etc, time is running out fast if I want to use it for my July 4th timeframe. I also have to travel for work next week, so I will lose some work time from that trip.

Still that being said, I got the doors mounted, adjusted, and the newer style striker patches installed.

So here we are, working doors:

https://youtu.be/ndVGthPadpY

 

[zluster]

Ok mocking up the steering:

Bars ready for weld:

How much I removed from one:

Brakes done and bled:

Sway bar links welded thanks to freerider:

Evaporative cooler is nice in the summer:

Axle painted:

Its alive! Driving stopping steering etc:

My helper after a long day:

Steering setup, will look at making a new track bar mount in the future:

Marking for the newer style door latch:

What I did was use some wax from a babybel cheese, and pressed it onto the back of the latch, then I put the latch on the door and then closed the door, Then I opened the door from the handle leaving the latch in place. This also aligns with where I saw other people having to put their latch.

And then....doors!

A pillar trims on and starting to assemble interior.

Got one fender on, I thought I had two red fenders, turns out I have 3 red fenders, but they are all drivers side fenders, and I also have 2 green fenders, both drivers side.......dammit. And I passed up the chance to pull an aftermarket red fender, or a stock green fender at the junkyard last week.....dammit dammit.

Hopefully one of those fenders is still at the junkyard.

 

[zluster]

Aug 1 2020:

Ok so not a lot of MJ work has happened in the past 6ish weeks. I've been traveling quite a bit during this time so I wasn't home to work on it.

So now I'm back into it.

I finally found the headlight buckets I robbed off of my patio decor YJ grill. Last night I installed new adjusters the buckets, and the LED headlights that I robbed off of my VW. Now I am very close to being able to install the hood, which then will allow me to adjust the fenders to get the gaps between the hood, fenders and header panel right.

But....I got no ****ing idea where I have hood hinges. I saw one around somewhere but I haven't seen two. So that might be yet another junkyard part I have to grab if I cannot find it.

And, I'm not sure what happened to the hood latches/springs that go in the corners in the MJ. So thats something else I need to dig up. So I'm really close to having the whole thing finalized on the front, but I gotta find some misc little BS parts before I can do that.....argh.

And....its already time to start trimming:

Finished getting the drivers seat belt install figured out. These are the newer seat belts and you have to trim the mounting bracket, and flip the pivot point and bucket so the retractor can be flipped to clear the B pillar trim. I'm going to be leaving trim off since I need to get my headliner figured out and that needs to be installed before the rest of the interior trim. But the seat belt is functional now.

I actually even drove it up and down the street, I used the parking lot of the elementary school to adjust my headlights a little bit and then drove it back over. might have only been 1000 yards or something but I actually drove the damm thing! I got my plates for it, but haven't gotten insurance setup, and my cat is still held in place with bailing wire. I'm going to get a section of exhaust pipe and push it behind the cab, then mount that and drive to the exhaust shop.

 

[zluster]

Ok, so you might not be able to tell, but I washed it, especially the doors, they had years of dirt built up on them for sitting outside for about a decade. I had to really scrub some parts to get the ingrained dirt off, and found out that the drivers window has weld splatter on the outside, WTF? so now I sort of want to replace that glass. I might have one.

Then I had to cut this much off of the raised sway bar end links. They were cutting into the tires near full lock! I still need to drill a hole for the end link, but........ My quick disconnects are way too fukking long! They are fort a lifted jeep but I forgot the quick disconnect is for connecting to a stock sway bar bracket.....doh! So now I need to modify the end links.

Finished getting the dash together.

I replaced the backlight for the shifter gates with LEDs, I think they are too damm bright!

And......4wd indicator works correct for the harness I had to build!

I also found the hood hinges, and the latches. So tomorrow I will be working on getting the hood installed and adjusted.

Plus.....rear bump stops, evap canister........and other stuff.

And, I bit the bullit today, ordered a double din touchscreen fancy head unit, the double din radio bezel, new speakers, and a backup camera!

I got this HU, which had me with the power button!

These rear speakers:
https://www.crutchfield.com/p_20646CC464/Kicker-46CSC464.html?omnews=11718430

These front speakers:
https://www.crutchfield.com/p_206DSC504/Kicker-43DSC504.html?omnews=11718430

This backup camera:
https://www.crutchfield.com/p_249CUB15/Crux-CUB-15.html?omnews=11718430

And this double din bezel:
https://www.crutchfield.com/p_120956554B/Metra-95-6554B-Dash-Kit.html?omnews=11718430

Gonna be sweet when its in! Should be here tuesday so I can get on it.


Ok I found all the hood parts I needed and got the hood on and the panels gapped. Oh and installed a new hood to cowl seal.

Dat Gap:

Then I removed the side stripe:

I figured out a good place to mount the carbon canister. I'll need to run some hose to it from the tank and the engine evap solenoid, but now I'll be able to keep the CEL off and not worry about passing emissions since its legit 100% factory emissions equipment.

So I placed it, marked 3 holes, drilled and tapped them, then used some factory M6 bolts to screw it in. Then I took a spare engine bay metal line, that was shaped nothing like the U I now have, and then straightened it and bent it into a U. Turned out nice.

Got the underhood light mounted!

Horn works. Cruise control lights up when turned on, but havent tested yet. Tomorrow I'm going to try and grab some exhaust pipe from a local place and then get the cat installed, and then I can get it over for the complete exhaust.

I ordered a bunch of rando **** today, some usb power stuff so I can put a charging port in the center console, some heat wrap. Still lots to do, but its getting damm close to being able to drive.

Now I sort of dread the things that are going to pop up once I start driving it. I just want it to be done and working, but I know I'm going to have the debugging/shakedown phase to get through as well.

 

[zluster]

I got a pair of these ordered to replace the interior lights located in the B Pillars:

https://www.partshubdirect.com/eura...-12v-auto-courtesy-flip-interior-light-a-7180

I also have the overhead console, and a KJ cargo light that will go in the headliner. Should be plenty of light in the cab with all that!

Ok so I got a temporary bit of exhaust in shoving the cat further back, the final location will change a little based on where the muffler needs to sit when the exhaust shop does it.

And then with the exhaust semi-permanently installed I can actually drive it on the road. So I ran down to Orielly to grab some tubing I needed for radiator overflow and the carbon canister. First trip was to the parts store!

Grabbed some pics during the golden hour:

So then I got a generic tent pole kit and made a new support pole for the wildernest, my friend with an MJ and wildernest measured his pole for me, both length and girth, and was even kind enough to send me an unsolicited pole pic. Using that I was able to make a replacement. Though I have to say my pole is now longer and thicker and blacker than his pole. Not that we care about such things in this day and age.

Which means I was finally able to put up the wildernest and have it stay open!

So tomorrow it gets a windshield, next friday it gets exhaust. And tonight I work on stereo.

It's getting closer and closer! Driven it about 20 miles not. I need to get a different speedo gear though. Pricey SOBs, I need to figure out what I need and get it ordered.

 

[zluster]

Ok so I got a USB surface mount connector with 2 usb 3.0 ports in it. I drilled a hole in the center console insert and mounted it in there, then I took another surface mount USB power outlet and soldering some wiring into the power outlet(right side) of the switch panel which is always hot. I plugged in one USB cord to that power source, and the other I ran up to plug into the back of the radio.

Then for the double din kit you have to trim a little and tap it over since its the air ducting. The right side just barely doesnt clear, so I just heated it with the heat gun and pushed it over. My headunit wasn't a fill depth deep so I didn't need to cut it all the way back, though what I did didnt really save me any effort so if I did it again I would notch the whole left side out anyway.

And then radio installed:

Already planning a trip:

And...I now have a windshield:

And then tonight I got the speakers installed, as well as new clips on the door panels to hold them on nicely. Forgot to take any pics of the speaker install, but you can still see the rear interior speakers.

 

[Ghost]

Glad to see you back updating this thread. Sad to see you ditch the Diesel. I'll be interested in your liek or dislike of the 8.8. We put one in my Son's MJ and I hate it They are just too narrow IMHO. He had a wheel spacer fail and it destroyed a rim and the spacer.