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Old 11-01-2009, 03:58 PM
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Some Problems I Need Help to Fix

New Jeep, So New Problems. I'm going to get cracking this weekend on fixing what I can, so here's what I've got. Any suggestions

1. Front and rear tube bumpers are a little rusted and the paint is peeled. Can I sand and rattle can with decent result ya think? I want to just paint them a matte black, but I'm wary about painting black.

2a. Transmission - I'm having a tough time shifting into 2nd and downshifting to 2nd from 3rd. It doesn't grind or pop out of gear, but i have to yank the shit out of it sometimes to get it into gear. It'll double clutch in okay sometimes, so I'm guessing syncro - but I don't know how much that's goin to cost me.

2. Rough Start - The engine will turn over but won't start the first time I turn the key. If I turn it again, then it starts up right away. I want to say it's something to do with the amplifier that's installed, but it happens consistently each time I cold start it.

3. Rear windshield wiper. It's not installed on the hardtop. I have the unit, but I've plugged it in and it won't turn on. Any information on the wiring or fuses?

4. Fender flares. I'm going to Kyrlon Fusion, and I've read some manuals on how to do it. Any other suggestions?

5. Hitch has a lock on it and it didn't come with a key. Suggestions?

6. Whistling is coming I think from the engine in 2nd and 3rd from 30mph - 50mph. Think it's due to the CAI, but I don't know if it's a vacuum leak. Only happens when I step on the accelerator.

7. Shift Boot - shift boot won't stay in. It's an aftermarket piece of crap, so I'm going to get an OEM one. Do I need a bracket to hold it in or is it just the rubber part that just stays in the hole?

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Old 11-01-2009, 04:18 PM   #2
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sand down the bumpes then spray them with a self etching primer then paint them flat black

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Old 11-01-2009, 04:27 PM   #3
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1) Shouldnt hurt to rattle can it but I would sand it real good and paint it all
2a) I am not too familiar with the way the synchro works however I'd make sure the boot isn't interfering with the shifting. Is there a lift?
2) I remember my dad's jeep doing that too, the solution escapes me.
5) You can probably pop i off with a good pry bar (aka long screwdriver)
7) Yes, you will need a plastic rectangular bracket that holds the boot in I picked one up at the jeep dealership.
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Old 11-01-2009, 04:48 PM   #4
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I think I see a throttle body spacer under the throttle body, so that and the intake will make a loud whistle. I have the same problem with the shifting and am trying to get the dealership to do something about it(I have an extended warranty).
2005 TJ Unlimited 4.0 6 speed
LoD expedition series rear bumper/tire carrier, BFG A/T 32x11.5x15, OME 2.5 w/ lj springs
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Old 11-01-2009, 08:48 PM   #5
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Ditto - 2a

I have a 2000 Sahara and I'll ditto the 2nd gear issue. It's almost like the slot is narrower for 2nd than the rest. Not bad enough to take it to the shop, but curious.
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Old 11-01-2009, 10:25 PM
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Originally Posted by billyb View Post
I have a 2000 Sahara and I'll ditto the 2nd gear issue. It's almost like the slot is narrower for 2nd than the rest. Not bad enough to take it to the shop, but curious.
EXACTLY! I just bought this, so I'm tight on funds for a month or two. It's weird, because it's only an issue every so often. Most of time I won't notice anything, then other times I'm yanking the hell out of it like it's locked out because I'm going to fast. Course, that's not the case at 10mph, so it's odd.

I've found a rebuilt tranny for $800 and used but working ones for $400, plus I've gone over the Haynes manual - and the drop and replace doesn't look TOO difficult. I'll have some experienced help, so what I'm probably going to do is just ride the shit out of the this tranny until 2nd is no more then replace.

The boot isn't getting in the way yet. At this point, it's half hanging out andd I'm debating just getting rid of it. The bumper will happen this weekend and I'll post some pics. It should look really good once I'm done! Afterwards, I'll be up in the Poconos and I'll do a photoshoot.

I remember my dad's jeep doing that too, the solution escapes me.
It's such an odd issue, so I'm hoping that something is just draining the battery. Let me know if you think of it or if your dad remembers.
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Old 11-02-2009, 12:28 PM   #7
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#2 Might be the valve that prevents the gas flowing back into the tank when setting. Can be replaced, but in the tank, so if you replace it, might as well replace the whole fuel pump assembly at the same time. My Jeep does the same thing when parked overnight or for an extended period. When I get in the jeep, I turn the key on, let the system build pressure while I put on seat belt, etc. Turn key off, then crank it, and it usually fires right up.

#5 Hacksaw or sawsall. Get some good blades, those pins are usually pretty hard.
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Old 12-05-2009, 10:56 PM   #8
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I read on another thread that the weather gets colder the 97-03 shifter boot material interferes with second gear,, as it bunches up and the stiffness of the rubber prevent complete engagement of 2nd, as the Jeep gets warmer the problem goes away. Is this your case? As I found there is a way to fit the 04-06 shifter boot to replace the older one, it solves the problem.
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Old 12-05-2009, 11:22 PM   #9
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Mine also came with a locking hitch but no key. I used a big screwdriver and a hammer and beat the crap out of it. Put the end of the screwdriver right into where the key's supposed to go and hammer the hell out of it. Quicker than anything that I had laying around to cut with.
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Old 12-06-2009, 12:00 AM   #10
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yeah the reason it isnt starting is most likely because of the flowback valve that makes sure the gas in the line doesnt flow back to the tank. Easiest way to test if it is ur battery or the valve is to jump start ur jeep on a cold start and see if it does it anyway. If so its most likely that valve and it wont hurt anything just might be annoying, and if its $150 worth of annoying u can get it the fuel pump replaced which has the valve contained in it.
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Old 12-06-2009, 12:53 AM   #11
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The shift problem - before replacing the whole tranny --
The previous owner may have put Slick 50, STP or something like it in the trans. Those make it too slick for the synchros to grab properly, making it hard to shift.

Try draining the trans, then refilling with the recommended stuff from the dealer. It may clear up the shifting problem. Get the right stuff from the dealer - avoid the the gear lubes from auto parts stores. There was a post on here recently that told about how the autoparts store's lube eats the brass synchros.

I've seem some brass synchro blocking rings that looked like they'd been partly eaten by rats, never knew why before.
It's no wonder the country is falling apart - stupidity abounds!
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Old 12-06-2009, 08:23 PM   #12
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You can try drilling out the lock. Start w/ a small drill and just keep going bigger until the solid part comes loose.
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Old 12-06-2009, 11:50 PM   #13
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I 2nd the idea on the drill the lock but on the other stuff I have no ideas what to tell u

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