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Old 01-31-2012, 10:07 PM   #1
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Toolman's 94' YJ - Log of Repairs & Mods

I decided to start this thread to help keep track of what I do to my Jeep, & plan to keep up with pics of what it looks like before & after.

I wish I would have done this from the start, but now is better than never I reckon.

My poor Jeep has sat for over a year waiting on parts to finish getting it back road ready. In the next month to two months I will be cleaning it up, replacing bad parts, fixing messed up wiring caused by the PO, & doing a few mods here & there to get it ready to put back on the road this year.

I got the garage cleaned out & ready for me to start the project then backed it in & got started right away.

I took a bunch of before pics that I placing below, then will take pics as I clean it up & get it closer to the way I want it.
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Old 01-31-2012, 10:14 PM   #2
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More before pics..................
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Old 01-31-2012, 10:16 PM   #3
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Pics of interior ........
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Old 01-31-2012, 10:19 PM   #4
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Pics of engine bay ............
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Old 01-31-2012, 10:20 PM   #5
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Can't wait to see it finished
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Old 01-31-2012, 10:21 PM   #6
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More pics of engine bay ...........
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Old 01-31-2012, 10:24 PM   #7
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Yet more pics of the engine bay .......
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Old 01-31-2012, 10:26 PM   #8
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Pics of some of the wiring I will be straightening up ........
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Old 01-31-2012, 10:29 PM   #9
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Quote:
Originally Posted by greenjeepgurl87 View Post
Can't wait to see it finished
Thanks, me neither, gonna be alot of work but gonna try & get it done in the next two months
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Old 02-01-2012, 12:16 PM   #10
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Great project Jeep. There is just something about black Jeeps.
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Old 02-01-2012, 12:17 PM   #11
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You need a bumper, have you picked one out yet?
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Old 02-01-2012, 01:03 PM   #12
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Thanks

Quote:
Originally Posted by Piper54
You need a bumper, have you picked one out yet?

lol, yea, I'm going to be replacing both the front & back bumpers sometime this year. I don't have any picked out yet. I am contemplating fabricating my own front bumper & will more than likely go with the black Smittybuilt rock crawler type bumper.

Haven't decided completely yet.
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Old 02-14-2012, 01:50 PM   #13
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Ok, did some major surgery this last weekend, still in the middle of the project, but here is some pics of what's been going on.

Old parts.....
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Old 02-14-2012, 01:58 PM   #14
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Cleaning, disassembly, cleaning & scrubbing, painting of a few engine parts, some of the reassembly.

Mainly, removed & cleaned the throttle body, intake, valve cover then replaced all gaskets. Replaced the old cracked exhaust manifold with a new style in which I put header wrap around the primaries before installing it on the motor. I then replaced ALL of the vacuum lines. Next step is replacing all of the dried out wire looms.

I ended up counting about 9 different cracks on the old exhaust manifold.
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Old 02-15-2012, 02:44 PM   #15
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I finished getting everything hooked up & started it up for a bit, once it straightened out from all the residue left by the Sea Foam & other cleaners I used, it now runs & sounds like a new engine. Has perfect compression in all cylinders as well. With no exhaust leaks ....woohoo!
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Old 03-11-2012, 09:57 PM   #16
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I just finished a thread I started about replacing the old, cracked, wore out exhaust manifold. Since this is the official repair & mod thread for this Jeep, I thought it would be fitting to put the link to that thread here --> Discussion: Replacement Headers for the 4.0L I-6
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Old 03-14-2012, 01:44 AM   #17
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Well, I got the radiator & electric fan in today, along with all of the brackets, belt, etc...

Ran it for about 30 minutes with no issues, looks like a test drive tomorrow sometime.
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Old 03-14-2012, 01:47 AM   #18
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nice project brother
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Old 03-14-2012, 01:50 AM   #19
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Quote:
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nice project brother
Thanks, I'm hoping to have it back on the road by the end of the month. Most of the little projects on it can be done after I get it back on the road.
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Old 03-14-2012, 01:54 AM   #20
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good luck i love my TJ
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Old 03-17-2012, 12:22 AM   #21
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I'm going to back it up a bit. The motor had a lot of build up & corrosion in the water jackets because the PO used tap water instead of distilled water & proper coolant. Before I installed the new radiator, I decided to flush the engine block VERY well. Being creative, I made my own block flushing system.

First, after I got the pump & hoses hooked up





I filled the first tub with 10 gallons of distilled water & 1 cup of CLR then kicked the pump on & let it run for about 3 hours.



Once that was done, I flushed the system with 5 gallons of distilled water, then circulated the system for about 3 hours with 5 additional gallons of distilled water.

Notice how much crap came out of the motor on the first flush



Then I repeated the process again with 10 more gallons of distilled water until the water was circulating clear.

Once that was done, I hooked up an air hose to the suction hose & blew the system completely out with compressed air for a while. Once that was finished, I started getting the new radiator ready to install.
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Old 03-17-2012, 12:33 AM   #22
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Got the radiator prepped & the electric fan installed that I'd had laying around for a few years, never used. Then bolted it in & hooked up the hoses.




While I was doing that, I had cleaned the fan shroud up & gave it a few coats of high heat clear coat to protect it & shine it up a bit.

I then wired the switch & relay up for the electric fan & ran all new wire loom to protect the wires.

Here are pics of the finished product at this time. I still plan to do ALOT more in the engine compartment from here.








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Old 03-17-2012, 12:39 AM   #23
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I took it for a test drive yesterday, it drove GREAT. I bet I gained in the neighborhood of 30 to 40 horses under the hood from the repairs & mods I did. It didn't try to over heat at all & ran around 200 degrees on temperature.

Only thing that happened was, that the electric cooling fan burned up after 30 minutes of driving it

So, I have a Flex-a-Lite cooling fan kit on the way from Quadratec to fix that issue. Other than that I have since put about 50 miles on it & is still running great so far (Fingers crossed)
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Old 03-20-2012, 08:16 PM   #24
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What is the benefits of a Electrical fan over a Mechanical? other then.. More wiring in a Electrical... Im wanting to keep my mechanical for the simplicity but.. Is it holding my Engine back at all?
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Old 03-20-2012, 08:34 PM   #25
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Quote:
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What is the benefits of a Electrical fan over a Mechanical? other then.. More wiring in a Electrical... Im wanting to keep my mechanical for the simplicity but.. Is it holding my Engine back at all?
It does sacrifice a little power with an inline 6 or V-8, but would have to be seen on a dyno to tell the difference. The main reason is they pull more air through your radiator when you are at slow speeds during crawling & trail driving. Stock fans at those slow speeds rarely pull enough air through & your motor will tend to want to run hot without one.

My new Flex-A-Lite electric fan kit should be here Friday
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Old 03-21-2012, 12:00 AM   #26
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Quote:
Originally Posted by The Toolman View Post
It does sacrifice a little power with an inline 6 or V-8, but would have to be seen on a dyno to tell the difference. The main reason is they pull more air through your radiator when you are at slow speeds during crawling & trail driving. Stock fans at those slow speeds rarely pull enough air through & your motor will tend to want to run hot without one.

My new Flex-A-Lite electric fan kit should be here Friday
Sweet! So Does the electric fan run all the time? Or only when the engine get's to a certain temp? Im not very good with wiring.. Is it a pain?
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Old 03-21-2012, 12:11 AM   #27
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Wiring is only a pain for the impatient, IMO. You just have to take your time & pay attention to what you are doing.

It depends how you wire it up. It doesn't stay on all the time unless it's wired up that way. Wiring them up can be as simple as wiring in a switch that feeds relay which will power up the fan, or you can run a thermostatic box that will kick it on & off at certain temperatures. The one that comes from Flex-A-Lite actually comes with one of those boxes & almost all the wiring hardware you need to do it yourself. When I get mine, I will do a detailed install thread to help ya out if you decide to go that route. Bear with me though, may take a few weeks before I have time to put it together.
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Old 03-26-2012, 09:54 PM   #28
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Got the new Flex-A-Lite electric fan & shroud put together. Modified the shroud to where the wire loom will run out the lower passenger side instead of running the bare wires out the bottom like it was set up. Also sprayed some high heat clear coat on the brackets to help prevent corrosion
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Old 03-29-2012, 03:50 PM   #29
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Looks great. Keep the pics coming. Looks like you are doing a thorough job.

Mike.
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Old 05-02-2012, 06:02 PM   #30
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I see a good start and a nice base for a turbo...... Looks good man..

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