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Old February 27th, 2010, 05:05 PM   #1
burnsie
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Default 94 YJ rehab

So a few weeks ago I bought a plain 94 Wrangler with 176,xxx on the clock, automatic, NP231, soft top and half hard doors. When I bought it it had not been driven in a year because the previous owner had broken the Ujoint and yoke and the radiator was leaking etc etc. It's rough for sure but the up side is that the motor is a Jasper that was put in 110,000 miles ago and the trans is also a Jasper that was put in 54,000 ago and they run pretty good. The body is rough but repairable, a few holes in the floor and body side, front fenders and rotten windshield frame etc.. I have had several XJ's so I kind of knew what to expect from the motor & trans and I have always liked the fact that you can replace basically an entire Wrangler from from catalogs and used parts!

Now the fun begins! The first thing to was to get it home and figure how bad it really was. When we got it back to the shop and started getting in to it we found that while it needed the new yoke and ujoints in the back the front axle ujoints were smoked and the 4x4 actuator was gunked up and kept it from engaging. After pulling it all apart and putting the ujoints in and taking apart the actuator we got the 4x4 to work smooth! A new radiator went in easy, we changed all the fluids except the trans and had a new muffler and cat put on. Now we have a driver! We checked out the brakes and found that the E brake cables are wasted but the front and back brakes are good. I bought a hard top, body mounts seat belts and 1" body lift here from buttercr125 (great guy) and have since picked up a set of hard doors off of craigslist and a windshield frame and glass here from mthead (another great guy). I put on a new set of BFG Allterrain 30's yesterday and things are starting to take shape!


While I have not had time to do much other than get it driveable with each part I get I'm getting closer to something that should be a good daily and fun to play with here and there on the trails and in the mud.

Since this is my first Wrangler I thought I would start a build/rehab log of the beast and look forward to hearing your thoughts about it.

Hope you enjoy!

burnsie
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Last edited by burnsie; February 27th, 2010 at 11:20 PM.
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Old March 1st, 2010, 11:38 AM   #2
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Well this weekend we made a bit of progress. We pulled the soft top off and went to work on removing the old rotted out windshield frame. I'm just gonna say that TORX bolts SUCK!!!! If you're not stripping the bolts you're twisting your sockets, we even used heat and nothing worked, what a pain!! After drilling out several of them we managed to get the old frame out. We cleaned up the hinges primed and rattle can painted them. We had to drill out a couple torx from the new windshield frame and then chased the threads. I wanted to paint the frame before we put it in but it was too cold so I'll do it in the spring. From there it went pretty smooth putting in the new frame and the hard top. After we had it all assembled we tried putting the doors on but they don't fit quite right and will need a little adjustment to close right. Need to do some work on the latching mechanisms too and we should be good to go for now. Dopey pics to follow
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Old March 22nd, 2010, 11:51 AM   #3
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Smile Getting there

The last few weeks it's been tough to get time to work on the jeep but I managed to get a few things done here and there.

After we got the hard top on it was time to see if the doors would fit right and open and close. I knew the doors needed some latch work but was amazed when I found out how F*#ked they actually were. I ended up having to buy new interior handles, latch and lock rods for the drives side, a whole new latch for the passenger side, locks and pull handles and window crank. The rods and latch were tough to find but I ended getting them from Georges Jeeps (he was great to deal with) and they fit like they should. Everything else I got from Quadratec and autozone. I had never really messed with doors before so it was exciting to say the least. After struggling to get the retainer clips out for the locks and trying to get the lock bar adjusted properly so the doors handles would function properly I got it done and they work great....Now... (read that last part, as it took me like a week and a half to figure all that crap out)

One of the other things I had been working on was getting it to run right. When I bought it, it had been sitting for a year and half in the guys garage and it sputtered and chugged under acceleration. After running a couple tanks of super through it and some fuel injection cleaner it wasn't any better. I put a new fuel filter in and some new plugs and cleaned off the nasty tip of the rotor and the nasty connectors inside the cap and for a few minutes it ran better. The key there is that it was only for a few minutes. When I put the plugs in I didn't bother to pull the wires off the cap to look at the connections on the cap or wires DOH! Seeing the error of my ways I pulled off a couple wires and quickly realized that they were the original wires, cap and rotor!!! To say they were FUBAR is an understatement, a couple of the wires were actually rusted to the cap!! After a quick trip to the zone I had what I needed and went to work. Here's the part where you say WTF! When I tried to get the rotor off the shaft it had basically seized to the shaft!! After wasting a ton of time trying to get the bitch off, I ended having to use the propane torch to heat it up a little and finally got it off... What a pain in the ass. Anyway, with the new plugs, wires, cap and rotor it runs like a champ.

Managed to get a few little odds and ends things squared away too like getting all the dash lights working, cleaning up the dash under the face plates, the rear speakers working etc. It turns out that the previous owner liked to cut the radio and speaker harnesses and now I have to sort through it all to get the sound bar and passenger side dash speaker working.

So next up is to cut out the rust over the passenger side rear wheel well and weld in some new steel as well as fixing the holes in the drivers side floor. Body mounts and 1" body lift are on the schedule for the next week (hopefully) and then fixing the other little holes and rust here and there. It's getting there a little at a time.

More dopey photos to follow..
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Last edited by burnsie; March 23rd, 2010 at 12:10 PM. Reason: spelling
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Old March 22nd, 2010, 11:54 AM   #4
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More pics of the progress.
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Old April 5th, 2010, 11:50 AM   #5
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Default This week's lessons...

Not a lot of updates, I've been up to my neck in other projects. The crucial lesson learned is NEVER cut the wireharness!! The guy I bought the jeep from really just hacked at things and never bothered to think about what he was doing or look at what went where. After fixing a bunch of ugly unneeded cuts he made to the stereo harness I finally got the sound bar working and put a couple new cheap speakers in it and now 5 of the 6 speakers work YAY! I managed to clean up some of the other cuts he made in the main harness that god only knows why he cut it in the first place!! The only other thing I have been able to do was put some new brake pads on it. This isn't really a big deal but when I bought it the PO told me that he and his dad had done brakes on it a while back but said it might need a set of pads soon. No big deal, I bought some pads and went to work. After getting the old pads out I looked over the calipers and found that the pistons were beat up like someone had put a prybar on them, that concerned me a little but not the end of the world. The thing that troubled me the most was when I was putting it all back together and found that the upper caliper hanger bolt hole in the spindle on the passenger side was stripped! I re-tapped it and of course the bolt was now too small.... What to do? Went Autozone to see if I could score a slightly larger bolt and found one close but I wasn't sold on it but bought it anyway. When I got home I started rumaging through my bolt box (thank you Rob!) and was able to find one that was about the same length but just slightly larger diameter and all is right for now. I know I am going to need to replace the calipers by the end of the summer but for now they are working well and that gives me time to find a new spindle mount. No dopey pics this time, I'm sure that will be a relief!!

Last edited by burnsie; April 5th, 2010 at 12:02 PM. Reason: brain fart
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