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Old 07-09-2014, 09:39 PM
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YJ rebuild

Hey guys,
I am new to this forum(just signed up,visited many times before) and was wondering if there is a forum on how to tear down a yj. I took my car to the shop to see if I could get parts fixed and long story short, they are going to charge a lot so I figured if I'm gonna spend money might as well go all in and do a complete rebuild. The frame is the biggest issue that is why I want to tear it down, either fix this one or get a new one. and then put it back together all over again. I've only had it 6 months and figured i'd have to fix parts and i think i got to attached to just sell and buy a new one.
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Old 07-10-2014, 08:09 PM   #2
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Is this a daily driver for you or a second vehicle? I'm in the middle of a tear down myself, I'd be happy to trade notes. I started by stripping the interior, then moved to the dash. Three or four things right away:
1. Buy and use PB Blaster liberally. It is a product that works, especially given time. Pick what you're going after, spray it 24-48+ hours before putting a tool on it.
2. Buy a Haynes or similar manual, or even better a factory service manual. Lots of great, essential info, and good reading on days you can't get to work on the Jeep.
3. I tried to stay away from power tools. If I can't get it with a 3/8" drive breaker with a 8" piece of pipe for leverage, I sprayed it with PB and walked away/onto the next piece.
4. Buy a good set of torx bits. Needs to go up to t-50 and down fairly low to get smaller hardware on the jeep. Always try a larger torx size, even if you think you've got the right size. T25 is real close to t27, and might make the difference between stripping a bolt or not.

Everything is bolted on/together. It's all rather straight forward, but take pictures as you go to aid your memory of what goes where.

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Old 07-10-2014, 09:25 PM   #3
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Also I would invest in stainless nut and bolt kit for reassembly when ready, well worth the $150.00. Have a lot of patience, if your jeep is rusty, I agree with morscerta and use PB Blaster and use a mini torch to remove stubborn nuts and bolts. Good luck.
Monster 93 Build Thread

1993 YJ. 6" BDS 38's
2010 Rubicon 5.5 Rock Krawler coilover 38's
2014 Dodge Ram sport 2" level 33's
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Old 07-11-2014, 08:04 AM
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Thanks for the input guys. My car is a daily driver but I'll be using one of my brothers cars to move around while its out of service.
I figured that the dash would be the next thing keeping the body from just coming out. I was also wondering about the stick shifter and the four wheel drive handle how do those come off?
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Old 07-12-2014, 10:34 PM   #5
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the shifter are connected under on your trans easy to get to just unbolt and pull them up from on top,,,after u un bolt the boot housing,,...i just did mine and it was very easy.....im starting a new rebuild of my 94...all due to putting in a new clutch kit...lol
4inch suspension lift,3inch body lift,4.0 5 speed,8.8 with disc,s,16inch moto metal rims ,and some 35s..
with trail rash..and getting 25mpg,s
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