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LoneWolfUSMC 04-30-2010 04:59 PM

Our new 20 year old YJ
Today is the first day of wrenching on the YJ and my first post on the forum. I have been reading for a couple weeks and thanks to you guys have a box of parts sitting here from Morris 4x4 Center.

I am a former Marine and current cop. I have a history of working on sport compacts and at least one 85 F150 farm truck that wouldn't die (other than a slow demise from metal cancer). I have built one sportbike from the ground up.

So the lease was set to expire on my wife's CX-7. She wanted something "sporty" that didn't scream "mom inside". We also wanted something with little to no payments. She settled on a Jeep and I didn't mind because I knew there were gobs of support and parts available.

We looked at the dealers and were amazed at the price they wanted for junk. So we kept hunting and found a 1990 YJ on craigslist. The price was right, it was almost totally rust free, had a new top and decent seats. The paint was recent, but with a ton of rock chips. The only two hits against it was the fact it was a I4 and that it had the dreaded missing fifth gear issue. We took it for a test drive and we were sold. We picked it up under budget and under market value (at least in this area) because the owner needed to thin out his stable (ironically the same issue I have with another car right now). It also came with a rear end, front end, hood and some other odds and ends.

I hit the internet and researched the issues, read the fixes and bought the parts.

The glaring issues are, Parking brake doesn't work. Rear brake cylinder leaking. Fifth gear missing. Shocks are shot (get seasick on the highway). Seatbelt reel was sticking. Leak under dash. No AM/FM antenna. Messed up wiring job on radio (quick fix so he could sell it).

I figure the safety issues are fist on the list. Seatbelts, brakes, shocks.

Today I gathered all the parts and tore into the drum brakes. It's been awhile since I rebuilt drums. With my trusty Haynes manual in hand I tore into it. I planned to replace both cylinders while I had everything apart (cheap insurance).

First problem.......who the hell uses two different sized lug nuts on the same wheel? They are the same thread size (thank god) but different nut size requiring two different sockets. WTF?

OK, past that. I tear down the brakes, shoot the cylinder screws and fitting with PB Blaster to loosen up the twenty years of rust. I let it sit for bit while I install the seatbelts. Back to the fitting, still tight so more PB and more waiting. (I am hosing both sides) So I hit the fitting with a nice fat wrench, it turns, no stripping....but so does the hard line. And it keeps going. Then twists off. DOH! I kind of expected that. Same thing on the other side.

A call to the local dealer shows one side not available and $80+ for the no Jeeping until I find a replacement for that.

At least I still have other stuff to work on while it's in the garage.

white91yj 04-30-2010 06:14 PM

YJ's are cool.

They look like "Jeeps with glasses" to me

answer to problem #1 - bubba

LoneWolfUSMC 04-30-2010 08:00 PM

Now I just need to locate some hard lines for the rear brakes. Looks like that's going to be a $200 part.

I know my friends are thinking "welcome to Jeep ownership".

crtaylor 04-30-2010 08:17 PM

you can make your own brake lines .with sections from a parts stor already fared with fittings.just measure and go get the right size and youll save a ton of cash:D

JDsDream 04-30-2010 08:19 PM

Welcome to the wonderful world of JIP (Jeep Induced Poverty) but it sure is a fun drive to the poorhouse and welcome to the forum.

Pylonpounder 04-30-2010 08:21 PM

I say make your own. Trust me, it's not that hard. I did it, I'm 17. Buy a roll of brake line from quadratec or jcwhitney, with fittings and stuff, and get a good craftsman double flarring tool (they are really cheap too) and practice a little before hand. Seeming as you are a fairly established mechanic, you probably know all that and don't want to.. but hey, it's way cheaper. A cheap crap flarring tool won't do well though.

birdhunter 04-30-2010 10:15 PM

A brake shop would make you one
for 50-60
Welcome brother

Snuffy115 05-01-2010 12:48 AM

For about $200.00 you can get a complete set of stainless steel hard lines form any of the online jeep places.

Vector6 05-01-2010 07:57 AM


Originally Posted by crtaylor (Post 613087)
you can make your own brake lines .with sections from a parts stor already fared with fittings.just measure and go get the right size and youll save a ton of cash:D

x2 !

bergy 05-01-2010 05:40 PM

welcome to the forum and good luck with the work

billy_YJ 05-01-2010 07:50 PM

welcome to the forum.

morphious 05-02-2010 08:26 AM

hi buddy welcome to the fun this will not be the last time she leaves you broke. first off the shocks are probably not bad that's the way these things ride. just wait till you lift it (if you are ) the ride gets nicer but the bounciness never really leaves. dont go the dealer ever unless you want to get raped on prices. look around if you dont personally want to screw with it you can get a shop to do it for that price. other wise if your have the money stainless is the way to go for sure. i assume you got the belts in ok and everything is good their. any more nifo needed just post it up some body will be here to give you a hand.
were here to help. oh and remember wave if you dont know about that then look up the jeep wave :wavey:

bck4more 05-02-2010 12:00 PM

Welcome and good luck. I lifted my jeep and therefore needed new brake lines so i had some made from a brake shop in town for $60. I wouldnt buy anything from the stealer lol just look around on internet and save yourself some money brother

whiteyj 05-02-2010 01:12 PM

Welcome to the forum and the YJ fold. If they were easy .....everyone would want to own a YJ!

Cardinal 05-02-2010 01:48 PM

And the fun begins. I had the same problem, Like a previous post said went to a local auto parts store got the appropriate lengths with flare nuts and used a spring to help bend them to shape(prevents kinking). I think it cost like 20.

csamn2007 05-02-2010 02:19 PM

PICTURES! welcome to WF.

LoneWolfUSMC 05-02-2010 07:02 PM

Got the universal sections from Autozone today and the bending tool. Going to give it a go tomorrow.

My wife posing in "her" new toy.

drox 05-02-2010 07:26 PM

Welcome to the forum

massyj 05-02-2010 08:38 PM

Welcome aboard
'90 YJ :punk:
Good luck and don't forget to wave! :wavey:

hotshotjus 05-02-2010 09:02 PM

welcome to the forum. looks like you got a nice one

yotefever 05-02-2010 11:00 PM

Welcome to the forum looks like you got a nice one there. :wavey:
I would recommend looking for Jeepers in your area and get with them.
They get together to work on each others jeeps so you can get some otjt for your jeep.

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