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Old 11-14-2011, 12:27 AM   #1
Join Date: Nov 2011
Location: Moscow ID
Posts: 5
1988 YJ Rehab

Greetings to Forum Members. Thanks for all your efforts to provide a reliable source for information.

I am just getting started on a complete rehab for a '88 YJ, 2.5 with 127,000 miles. Engine has been abused and rather than try to do the machine work to bring it up to par, I am beginning with an engine exchange.

Have ordered a long block and while the engine is out, am thinking that this would be a good time to:

1. Replace the water pump
2. Recore or replace the radiator
3. Replace the altenator
4. Replace the starter/solinoid

Anyone have suggestions about these items - best brand, best value, best parts vendor? I have been searching web stores and am really surprised at the vast array of options. I could really use some advice about this. For example, the stock altenator produced about 65 amps. I note that replacement items are available up to 300 amps - perhaps even more. And there are numerous brands.

Same with starter/solinoid. Same with water pump, same with radiator.

Also, will have to replace the hydraulic cylinder in the clutch housing and probably the clutch - yes the cylinder is leaking.

Is there anything else I should be considering while the YJ is undergoing the engine work???

I am not trying to build up a show car, but I do enjoy having a machine that is performing as reliably and fun as can be. (Have nurtured a BMW R80/7 since new in 1978.)

I recently retired and bought this Jeep a few years ago - just now getting the project started (had to get the refrigerator list handled before I could get the time to work on the YJ )

The snow is starting to fall here and I will use the winter to get my rig running right.

Hopefully you would be willing to help me along the way.

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Old 11-14-2011, 10:40 AM   #2
bc3_Jeep's Avatar
Join Date: Nov 2010
Location: NE corner of Iowa
Posts: 1,711
If you have an internal clutch slave cylinder (pretty sure you do), I would retrofit THAT if you are going to all the other fixes.

"For Gawd's sake, put a RELAY in there or you could burn the whole damn Jeep to the ground" ...this quote brought to you by people who do not understand the law.....Kirchoff's, Ohm's, or Faraday's.
Violation of KISS shall always ring false in TRUE engineering. - ME___
Had 75CJ5, 89YJ, 93YJ. Have 82CJ7 & 95YJ____Not one burnt yet due to lack of relays.
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Old 11-14-2011, 04:25 PM   #3
guardian262's Avatar
Join Date: Oct 2011
Location: Baltic, CT for the time being.
Posts: 89
If you have any rust issues on the front frame and suspension (say it ain't so) it sounds like a great time to prep and paint or undercoat while the engine is out. It's not often you get all that room to play.

I know I plan to do that in the future, and even though I have no rust issues, I have no idea what the PO used to coat the frame.

As for the alternator, people seem to run something like a 136 amp alternator if they run accessories.

If you are comfortable, I would also go through the wires to see if any have degraded insulation which has the potential to cause future problems. Missing insulation on sensor wires can sometimes be difficult to diagnose.
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Old 11-15-2011, 10:22 AM   #4
Join Date: Nov 2011
Location: Moscow ID
Posts: 5
BC 3 and Guardian,

Thanks for your suggestions. The body is rust free, however, I will plan on doing the undercoat - great recommendation.

Also, I had not thought of the wiring. I do have the Haynes manual which has complete wiring diagram. I am comfortable with wiring so will do that as well.

YES - the internal clutch slave cylinder is a problem - it is leaking and I suspect it has compromised the clutch plate. Before I put the Jeep on blocks, I noticed that when in reverse, the clutch was slipping and chattering.

Has anyone out there redirected the slave cylinder outside the clutch housing? If so, what did you do????
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alternator upgrade , engine replacement , starter replacement , water pump replacement

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