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Old 12-16-2019, 09:18 AM
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'88 Sahara Family Use Jeep

Picked this one up so My kids can go wheeling without destroying my beloved Tonka. (Replaced two windshields, neither of which I was behind the wheel, LOL).

Not exactly starting out with the Ideal Setup, But I swapped it for the Silverado with a kid moving home to Cali. and no way this will clear emissions. He had it for about 3 mos. before he found he was in over his head. But it does have a few Goodies that work for my purpose, so we're going to build it Boring and Reliable.

Also want to use it and the thread as a helpful reference point for new guys that want to see some how to pics and tricks.

Here's what I got the day it came home...

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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-16-2019, 10:18 AM   #2
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So what are the Boring and Reliable plans??

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95 YJ " Bleu Belle" | 4.0L 5-spd | RE Extreme 4.5" | Dana 44's | 4.88s | Eaton E-Lockers | 35" MTRs | 15 x 8 AR Baja's | 1" Daystar BL | MetalCloak 6" Overlines | Adam's Driveshafts | NP231HD | JB Super Short SYE | BDO 1" MML | Warn XD9000i | Hella H4's |

95 YJ "Gecko" - under construction...
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Old 12-16-2019, 05:42 PM   #3
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Looks like a great start.
Please post the specs and some more pics.

Good Luck, L.M.
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Old 12-16-2019, 07:45 PM
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So what are the Boring and Reliable plans??
Haven't got anywhere close to finding out everything that's half assed, missing, broken, leaking or empty. Frame and Tub are pretty solid, lots to take apart repair, replace, clean and lubricate before any changes get made.

First steps...
Change all fluids
Check out gears, u-joints, steering gear, brakes, hub units, springs, shocks, bushings.

Electrical is a complete mess, auto windows, stereo, KC's, air compressor for locker all pulled off of totally in-appropriate power sources, electrical tape everywhere, Zip ties pulling on connectors.

Lots of delayed maintenance, Here were my first clues...
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-16-2019, 07:57 PM
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Current Stat's

'88 Sahara edition, 4.2l. BA/10, NP 231, No SYE (Yet), D35 w/ARB Locker, D30 open(still have to verify but drives like 4.10 gears), older Rancho shocks, What I believe to be an older warn 7.5k winch, unknown springs.

Can anybody help me out with ID on these bumpers?
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-16-2019, 08:02 PM
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Got a nice New Radiator on it, but PO bypassed the hoses, and the thermostat unless this is the coldest running Jeep in AZ, won't get over 120* -140*, Which leads me to believe it was not flushed either, seems a shame to waste all that pretty New Green coolant.

Add That to the list. All New hoses everywhere.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-16-2019, 08:50 PM   #7
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Quote:
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Current Stat's

'88 Sahara edition, 4.2l. BA/10, NP 231, No SYE (Yet), D35 w/ARB Locker, D30 open(still have to verify but drives like 4.10 gears), older Rancho shocks, What I believe to be an older warn 7.5k winch, unknown springs.

Can anybody help me out with ID on these bumpers?
That's the same garbage bumper I got from Amazon
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Old 12-16-2019, 09:27 PM   #8
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Here it is on mine
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Got it at last likes this.
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Old 12-17-2019, 12:50 PM   #9
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That rear bumper sure looks huge. I'm sure that will snag on all kinds of stuff on the trail. It looks an awful lot like a Smittybuilt JK bumper that I am modifying to fit a Liberty for a buddy. I actually have two of them. I'm going to modify the other to fit my YJ, but will be cutting a lot of steel off of it.

https://www.amazon.com/Smittybilt-76.../dp/B003NNZ1L4

Aside from some maintenance stuff, it looks like a pretty solid start.
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Old 12-17-2019, 01:08 PM   #10
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Congrats! Looks like a great project you've got!
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Old 12-22-2019, 09:08 PM
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Still trying to figure out all this mess, Where to start what to keep, what to pull and start over.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-22-2019, 09:33 PM
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Some wiring under the hood that will be first.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-22-2019, 09:42 PM
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And a whole bunch more under the dash... and that's just what I found before I start pulling the Bezels. All gauges are acting Erratic so it's pull the cluster, clean the ribbon, connectors and grounds. Take out the automatic window rollers, re-route the wiring if I decide to keep them, and a whole lot of chasing down cut off plugs and hot wires pulled from everywhere to run the lighting and locker switches.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-23-2019, 08:46 AM   #14
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Yep... that's a little messy.
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Old 12-23-2019, 04:04 PM
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Even though it was way down on the list of "necessary", I went ahead and ordered the HEI From Summit today, Gonna pull the dash panels, go through all the wiring, pull the computers, and leftover wiring in the engine bay and get everything out of my way so I can get the engine bay clean and tidied up, right now there's so much crap in the way I can't figure out what to do first.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-23-2019, 08:52 PM
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Started pulling wiring, PO was either color blind or scrounging wire to cut costs, different colors, wire gauges crimped together, everything Zip tied to the heater cables, fuse block over-tapped big time.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-23-2019, 09:34 PM
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So what are the Boring and Reliable plans??
"Boring and Reliable" you ask? At this point the clear coat is so far gone that a nice paint job is out of the question. The stock carpet is soaked with gear oil and stinks to high heaven. After nailing down all the leaks, its gonna get a good cleaning inside and out.

I've sat back and figured out the minimum I want to do for my family members to take it out.

Project List...
Interior after cleanup

Simpler to operate Sony Stereo with some new JBL's front and rear
Get the blower motor working.
Old front carpet out, new Bedrug kit in...Keeping rear kit as it's in good shape
Relocate Posi-lock Cable
Cleanup and condense Lighting and locker switches
Complete set of new Door and Window seals.
Re route and add weathertech connectors for power windows for door removal when wanted.
Clean some more...LOL

Engine bay

Keeping the Weber... for now
HEI Distributor, Plugs, 8mm Wires, Pull the rest of the emissions and computer, Cleanup balance of wiring.
All new belts, hoses and rubber fuel lines.
Complete Fel-Pro Gasket set on standby to replace as needed.
Direct Battery connect Dual lighting harnesses for H-4's and KC's.
Maybe a reservoir for the locker onboard air
Back to my muffler guy for all new exhaust, manifold back.
New cowl and hood seals

Suspension/Drivetrain

Complete fluid drain and replace diffs/trans/tc
Keeping the "Frenchie" BA/10 For Now...
RE 4.5" Extreme duty springs front and back
New Rancho rs5000x Shocks.
Remove the TC drop Kit
New AA SYE / Adams Double Cardan Rear Shaft
R&R Fuel tank, valves, hoses. Clean tank and most likely replace sender.

Get that done over the next few months and we'll see how it goes from there.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 12-26-2019, 06:41 PM
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Got finished going through all the wiring. Pulled everything not stock, did a little dusting, routed everything back up and out of the way.

4 Separate Taps off the fuse block causing a short to the Brake light circuit, blowing the fuse, Zip ties pulled brake light switch off of switch, got brake lights back.
Heater circuit tapped not connecting the blower motor circuit, got that fixed and blower working.
Windshield wiper hose replaced and hanging down halfway through the run with the wrong size tubing leaking on the drivers side floor. Shortend up and run back up against the firewall.

End of Day, everything stock working as intended, no wires hanging down, ready to finish cleaning dash bezels and replace after the Stereo and LED dash lights arrive.

HEI Showed up today, tomorrow gonna get that install and start on the engine wiring.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 01-20-2020, 09:09 PM
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Been working on the wiring for the last couple weeks one wire at a time. HEI is in all the computers out. Other now useless wiring under hood out and cleaned up. Had to pull all the accessories out to get the rats nest out of the way so the heater cables would have room to move. (PO had wired everything one piece at different intervals into a complete cluster f___.)
So I have these "appliances" to go back in

a. KC's on the window frame.
b. Rear facing LED's in the rear bumper.
c. Maybe a small light bar or 3"cubes on front bumper hoop above winch cable.
It's a lot more lighting than I need, but the kids like to go out at night, go figure.

d. ARB compressor
e. Rear ARB Locker
f. CB
g. Hitachi power Window kit. (not really a fan but it's hard to find a decent hand crank and my son thinks it's cool.

So instead of overtapping the stock fuse block again, or adding an assortment of inline fuses, I opted for a 100a dual feed Fuse panel I found that will allow me to feed one side with Key-on power, through a relay, and the other side constant direct from the Battery.

With everything out loose it allows me to run all the lighting wires to my rockers along with the ARB harness, keeping everything in one run rather than the six or seven I had all over the place. my final dilemma is whether to mount fuse block under dash or under hood.

h. Headlight harness for H-4's. Direct wire off Battery

Stereo needs to go in, button up the Dash and on to Drivetrain, Have yet to take it out for a good bouncing and see what else is in need of extra attention.

Timing set is sitting on the bench waiting for a day without interruption, not the kind of thing I want to start and walk away from for acouple days.

Ditching the Weber, cant seem to get it to tune the way I want, for a new 2150, Not sure but maybe the 38 is a little more than the 4.2 needs.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 01-21-2020, 09:12 AM   #20
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Cool. It sounds like you are making good progress.
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Old 01-21-2020, 09:31 AM   #21
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Give us what we want!!!!

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95 YJ " Bleu Belle" | 4.0L 5-spd | RE Extreme 4.5" | Dana 44's | 4.88s | Eaton E-Lockers | 35" MTRs | 15 x 8 AR Baja's | 1" Daystar BL | MetalCloak 6" Overlines | Adam's Driveshafts | NP231HD | JB Super Short SYE | BDO 1" MML | Warn XD9000i | Hella H4's |

95 YJ "Gecko" - under construction...
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Old 01-23-2020, 08:34 PM
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Got a million of them, Maybe I guess I'm trying too hard to come up with the perfect wiring harness, Keep trying to get the best location for fuses and routing of all the wires so I don't have to yank the whole 'friggin' dash every time I want to access something under there. But I promise when done it will look like a work of art. Right now we're still in the abstract Picasso period.
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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 01-25-2020, 10:38 PM
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Started putting wiring back in after deciding how and where it was going to end up.

1,2, Harness for KC's on the window with bullet connectors for future service/swap. Ran it up and across the top through the chase above gauges.

3, Added an additional dedicated ground for the gauge cluster.
Added dedicated ground buss behind Glockbox for everything requiring grounding.

Power windows wired back in, decided to keep them, left the disconnect plugs accessible to easily remove doors.

4. See Post #16 for some of what I started with but this what I was able to get cleaned up.

5. Accessory Fuse panel mounted with dual 14ga Key-on and 12ga Direct busses.

May not seem like all that much, but trying to put everything back so nothing is in the way of anything else is really taxing my OCD. Got a 3 rocker panel coming tomorrow to fit into the stock dash location to finish up the wiring and dash, then on to figure out the linkage for the new Carb.
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__________________
'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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Old 01-26-2020, 09:39 PM
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  #24
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New rocker switch panel showed up today, perfect size to fit where the Factory rockers mount lower left of the column, and was able to get the dash wiring completed tonight. Jazzed to finally be able to move on to stuff with moving parts.

1. Out of the box prewired with three lit rockers
2. Pulled defrost and fog light switches (not used)
3. Cut back out to accept switches.
4. Sized up panel, drilled to mount plate, Dropped in the Arb rockers.
5. All buttoned up, nothing hanging down, finished.
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__________________
'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Magnaflow Ex. AX-15, NP231, Adams front shaft, SYE, 31x10.5x15 BFG KO's, 2 1/2" RE Springs, 1" BL. RS5000x, Hella H-4's, XRC 9500 Winch
'88 Sahara, 4.2, MC-2150, HEI, BA-10, 2 1/2"Magnaflow, np231, Hardtop, 31x10.5x15 Cepek FC's. '06 WK, '05 WK,

FSM Manuals https://www.dropbox.com/sh/0vfmk6jc5...v7lceZk7a?dl=0
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