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Old 04-21-2019, 10:34 PM
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2003 Black Wrangler X - Texas Jeep

Well today is officially the first day of the TJ's life with a Jeep Lover. I have big plans for this little ride. Tomorrow we start with a cleaning, vacuuming, and inspection. I plan on replacing the valve cover and gasket later this week, which hopefully is the source of the driveway drips. If that isn't it, then its likely the rear main seal.


Here are my "Before Pics" more to come as the journey progresses.


Bob

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Old 04-22-2019, 12:04 PM   #2
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Congratulations, looks like you have a solid base to start from!

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Old 04-22-2019, 02:57 PM
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Day two included the following tasks:

Examine the drip. Not a drip was left overnight, apparently it on drips after it has been running
Remove the front and rear bumper end caps.
Removed the front and read fender flares and short running board/flares
Removed all interior carpeting
Vacuumed out the interior, lots of sand and leaves, top must have been down while parked under a tree
Removed the back seat for carpet removal and vacuuming, dusted it off and vacuumed too
Removed the aftermarket trailer hitch
Hosed off the first layer of dirt, exposing a millennia of bug guts. I'm going to need a paint safe solvent to removed thousands of bug guts.
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Old 04-23-2019, 01:41 PM
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Day 3

Mores cosmetic tasks, while waiting for my boatload of part to be delivered. Today I:

1) Used Formula 409 to wipe out cargo floor, passenger and drivers foot wells, interior body sides
2) Washed windshield three time to get all the grime and bugs off. Still a few streaks, but 99% better than it was
3) Took off all four wheels to inspect rotors, pads, drums and shoes. All I can say is, I won't be driving it on the street until they are all replaced!
4) While Jeep had its tires off I inspected a few bushings, and all I can say is "what bushings?"
5) Used the tire take off to replace all the lug nuts. The ones on there were nasty, partially rounded, a mixed set of locking lugs has been removed and an inexpensive set of chrome lugs ahs been put on until I replace all the tires and wheels. Tires look dry and cracked.




I'm headed to Walmart later today for a shopping list of fluids - diff, engine, tranny, power steering, brakes, anti-freeze, washer fluid. Next up, order the replacement brakes.


Ps. I'm seriously considering bedliner for the floors, but the prep, removal of the seats and console sounds a bit much, as well as removing all drain plugs and back seat/cargo brackets. Someone tell me it is worth the trouble by showing amazing pictures of theirs!!
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Old 04-24-2019, 11:03 AM   #5
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You have already removed the rear seat. Removing the front seats is not hard. Neither is removing the console. Albeit, it does take some time. Just tape up what you don't want sprayed.

I plan on doing it to mine, but I have a lot of other things going on with mine right now. I did spray the underside and am very happy with it. (Pics on my build thread.) I used this stuff.

One thing is for sure, you won't regret doing it. However, you might regret not doing it now while you have the interior already half taken apart. Decisions, decisions.
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Old 04-25-2019, 10:19 AM
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Quote:
Originally Posted by JeepTed View Post
You have already removed the rear seat. Removing the front seats is not hard. Neither is removing the console. Albeit, it does take some time. Just tape up what you don't want sprayed.

I plan on doing it to mine, but I have a lot of other things going on with mine right now. I did spray the underside and am very happy with it. (Pics on my build thread.) I used this stuff.

One thing is for sure, you won't regret doing it. However, you might regret not doing it now while you have the interior already half taken apart. Decisions, decisions.

I've watched a few videos on applying the bedliner and I'm 99% convinced that is what I'm going to do. Next week (visitors this weekend) I am going to remove the front seats, seat belts (torn and tatty anyway) and soft-top and begin to mask off areas where I don't want liner.


Question: should I remove the back seat latch bases and re-paint with just black spray paint or should it all get bed lined? I'm thinking remove and paint.
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Old 04-25-2019, 03:07 PM   #7
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Quote:
Originally Posted by BobK View Post
I've watched a few videos on applying the bedliner and I'm 99% convinced that is what I'm going to do. Next week (visitors this weekend) I am going to remove the front seats, seat belts (torn and tatty anyway) and soft-top and begin to mask off areas where I don't want liner.


Question: should I remove the back seat latch bases and re-paint with just black spray paint or should it all get bed lined? I'm thinking remove and paint.
Good decision. I know it seems daunting. But, once you get going, it's a piece of cake. But, I can't stress enough to tape up what you don't want bedlined.

Yes, remove them and paint them.
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Old 05-05-2019, 09:01 PM
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The project build got new front rotors and pads, as well as read drums and shoes, all nice and shiny (for now).


The project moved forward this week with more stripping of roll bar covers (nasty looking), passenger front seat (prep for bedliner spraying) and de-greasing the engine prior to new valve cover and gasket, new positive and negative terminals to starter, ground and alternator, new serpentine belt, radiator and heater hoses, then new plugs and coil rails, and finally air filter and oil change/filter.
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Old 05-06-2019, 09:25 PM
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Day 16 of the Build

Roll bar covers removed, sound bar and wiring disconnected, passenger seat removed.

New seat belts and roll bar covers to be delivered this week.

Visited with local LineX, $800 for interior, $4500 for exterior (as long as its black) that is too rich for me, home spray of the interior is going to have to work.

If I didn't mention it earlier in the thread, front rotors and pads replaced over the weekend, read drums and shoes replaced too.

The plan is to replace the valve cover and gasket in the next day or so, then de-grease the engine and engine bay before replacing other engine components.

PS. Does anyone know the trick to removed the plate for the shifter (Park, Neutral, Reverse, Drive, Low) from the shift lever itself (as you can see in the pic below)?
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Old 05-07-2019, 09:05 AM   #10
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Quote:
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Visited with local LineX, $800 for interior, $4500 for exterior (as long as its black) that is too rich for me, home spray of the interior is going to have to work.
Spraying the liner is pretty easy, especially if you buy the kit that includes the sprayer (and you have an air compressor). The material is very forgiving during the spray. But, as mentioned before, mask off what you do not want sprayed. And, then pull the tape while the liner is still tacky. Once it hardens, it will be difficult to get all the tape removed.

Quote:
PS. Does anyone know the trick to removed the plate for the shifter (Park, Neutral, Reverse, Drive, Low) from the shift lever itself (as you can see in the pic below)?
You'll have to remove the auto shift knob to remove the shift indicator plate. It just pulls off, but you'll have to put some muscle into it. Just keep your knuckles away from the dash and your face when yanking at it.

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Old 05-07-2019, 03:13 PM
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Quote:
Originally Posted by JeepTed View Post
Spraying the liner is pretty easy, especially if you buy the kit that includes the sprayer (and you have an air compressor). The material is very forgiving during the spray. But, as mentioned before, mask off what you do not want sprayed. And, then pull the tape while the liner is still tacky. Once it hardens, it will be difficult to get all the tape removed.



You'll have to remove the auto shift knob to remove the shift indicator plate. It just pulls off, but you'll have to put some muscle into it. Just keep your knuckles away from the dash and your face when yanking at it.

https://youtu.be/NT1k_ejFt5o



That's too funny. Minutes after posting this question, I decided to check YouTube and found this 18 second video and wondered, what could they tell me in 18 seconds......well he told me how to take it off. I got up from the computer, walked to the garage and had the shift top off in less than 8 seconds. Thank you!
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Old 05-10-2019, 02:14 PM
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The project continues to move forward after the broken bolt situation.

Yesterday and today, I wrestled the valve cover and gasket out of the Jeep. There were two obvious spots where oil was clearly leaking from under the gasket, the back of the valve cover (as expected and predicted) and from the drivers side between the valves for the back two cylinders. Both locations have a lot of crud build up and the back of the engine was clearly oily and running down the backside of the engine/transmission. I'm hopeful, but not 100% certain, that I might not need a rear main seal job.

While losing the nut that holds the ground wire to the engine, I miraculously found one of the valve cover bolts that had apparently been lost the last time that gasket was replaced. When I removed the valve cover bolts I noticed that one of them looked slightly different, despite having the same threads. Turns out that little bolt was hidden on a bracket near the transmission. I eventually found the 18 mm nut that secures the ground wire to the engine. Of course that didn't stop me from dropping it three more times while trying to thread it back on at the end of the job.....LOL

Here are the during and after pics (forgot to take a before, but you can imagine).

Headed out of town for a few days to visit my 90 year old Mom for Mothers Day, but upon my return I'm headed to the quarter cash wash (been a long time since it cost a quarter) to spray engine degreaser and power wash the engine, transmission, transfer case, and both diff's before the next series of projects.

Does anyone know the name (or part number) for the honeycomb aluminum insulation stuff to the right of the valves? Mine is torn and nasty and would like to replace.
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Old 05-14-2019, 08:21 PM
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I've been out of town for a few days visiting my 90 year old Mom for Mothers Day.

All I could think about while I was gone was the next few tasks on the TJ. Tomorrow, weather permitting, I am taking it to the car wash to powerwash the engine compartment, transmission, transfer case and both diffs.

While I was gone, my new diff covers from Alloy USA showed up, so I'm hoping to get them installed later in the week. Here is what they look like:

For the Dana 30 For the Dana 35
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Old 05-23-2019, 11:19 PM
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Sorry for so long since my last build thread post. Between working on the TJ, and normal spousal to do items, I've been swamped.

Since my last post, here is what has been accomplished:

Flushed radiator, heater core, engine block, and overflow bottle
Installed new thermostat and housing
Installed new radiator hoses (upper and lower)
Installed new heater hoses (both)
Installed a new vacuum line along back firewall
Removed old coil rail and spark plugs
Compression tested engine - pretty normal for 208,500 miles
Installed new spark plugs and coil rail
Removed old front and rear diff covers and installed new red aluminum Alloy USA covers and new diff fluid

I still have a long list of refurbishment tasks before I even get to upgrading it. I've decided to do a 1" body lift that also replaces the existing bushings, since they are dry and cracked. Then I will do a 2" coil and shock lift along with replacing both front and rear track bars, an upgraded steering system, etc. I'm

Meanwhile, I'm pretty sure I need a new rear main seal, the drip continues even after the new valve cover and gasket. I'm going to take it to a shop to get done since my garage is not equipped for the task. While the shop has the oil pan off are there some other things that I get them to do since the bottom is opened up?

While I was replacing the vacuum line, I need to removed the battery and batter tray to get to where it terminates and decided to wire brush the surface rust off the battery tray and give it a quick Rustoleum spray, there was hardly any rust but I thought I would clean it up while I had it out.

The pics below are: the spray painted battery tray, the engine compartment with all the new shiny stuff, and a before and after pic of the front diff, I got too carried away with finishing the rear that I didn't get a before pic, but all you have to do is look under any other 2003 Jeep TJ with a Dana 35 and you'll see what the before looks like....LOL
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