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Old 11-12-2017, 11:07 PM
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Newly Minted YJ Owner

Hi everyone,

Long time Jeep owner just acquired my first YJ. Previous Jeeps were all Cherokees and Grand Cherokees, but I am really excited to dive into fixing this Wrangler up.

It's a 1995 Wrangler Rio Grande 2.5L. The top needs replacing, there is a decent amount of rust, and it needs plenty of cosmetic work. Any cost-effective recommendations for fixing the rust and improving the paint job are appreciated! I have done some basic work on my cars, but this will be my first big project.

Looking forward to reading more of the posts here and learning as I go!

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Old 11-13-2017, 10:25 AM   #2
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love the yj, looks cool even with rust and peeling clear coat.
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Old 11-13-2017, 10:54 AM   #3
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Before you do any paint work, Heat the torx bolts that hold the windshield frame to the hinges. It seems that the factory applied Loctite to all the torx fasteners and about 500* is needed to break the bond.
Replace the windshield frame. When they're rusted as bed as yours, it's not even close to practical to attempt a repair. If your windshield is still in good shape, you can put this off for a while you do other things to make your new toy reliable and modded to your satisfaction.

As you replace the windshield frame, make sure the hinges will allow the frame to fold forward. If they're frozen, heat the hinge pins to break down the rust inside and try to oil them. Heat, oil, heat, oil. Makes a lot of smoke, but eventually the heat & oil will free them up.
If your cowl to windshield frame gasket is shot, try to find an OE MOPAR gasket. The aftermarket ones seem to not fit too well.

Also, you'll need a set of quality torx bits. You can cheap out on some other tools, but you'll want the best set of torx bits you can afford.

Another bit of good advice is get a Factory Service Manual.

Good Luck, L.M.
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"Wrangler....It's not just a vehicle, It's a lifestyle".
.................................................. ........................
1987 YJ-4.2L-Standard Shift- Re-manufactured Carter Carb-2" body Lift-31X10.5X15 BFG KOs-190K Miles No back seat.
HEI distributor with computer and all related relays and wiring removed.
12K Badlands winch with dual batteries.
Warn front bumper. Matching imitation Warn bumper on the rear.
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Old 11-13-2017, 10:58 AM   #4
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Welcome to the forum!

First question is: do you plan to modify it, or are you looking more at restoring it? That can take the process in different directions at times.

As far as the windshield frame goes, if there aren't any holes rusted through you might get away with sanding it out and repainting. But from the looks of it you might be better off to replace the frame. It's one of the problem areas on YJ's.
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Old 11-13-2017, 09:44 PM
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L.M. -

Thanks for the advice! First thing I did was get the FSM. For the windshield, I appreciate the insight. That was going to be one of the first things I looked into - replacement vs. cleaning it up.

Chris -

I plan to start with just restoring it. Mods may come later, but I do not have anything substantial planned.

Thanks for all the advice so far!
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Old 11-13-2017, 10:11 PM   #6
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This is what you'll find when you pull the windshield.
And, this one doesn't have as much rust as yours.

What I'd do is simply remove it and install a new frame. Once the jeep was painted, I'd have the glass company install a new windshield.

Then you should be able to get $25.00-$50.00 for the old windshield & frame from someone that needs the glass and doesn't care about the rust.

Good Luck, L.M.
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"Wrangler....It's not just a vehicle, It's a lifestyle".
.................................................. ........................
1987 YJ-4.2L-Standard Shift- Re-manufactured Carter Carb-2" body Lift-31X10.5X15 BFG KOs-190K Miles No back seat.
HEI distributor with computer and all related relays and wiring removed.
12K Badlands winch with dual batteries.
Warn front bumper. Matching imitation Warn bumper on the rear.
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