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Old 04-29-2017, 11:50 AM
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95 YJ 2.5L 5-speed Build

Decided I should start a build thread to follow my progress. About 2 months ago I decided that I was gonna trade in my 08 F350 Lariat CCLB that I was in love with. So my wife needed a new car so I traded in the truck and got her a new car.
Found a guy looking to trade his Wrangler for a small car for his grandson. Great! Fixed up the wife's old car and traded for a 95 Wrangler 2.5l 5-speed, 4 1/2" suspension lift, 3" body lift, huge 35" toyo open county tires on ugly 20" rims, soft top with half doors, 205,000 miles but ran pretty decent and not any bad leaks. Well it's been 2 months almost and I've done a lot of work already.

I'll try to get photos up and more info after work.

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Old 05-02-2017, 10:06 AM
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Alright so here are some photos from when I got her. Hopefully this photo thing works.

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Old 05-02-2017, 10:09 AM
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Apparently the photo thing didnt work. Here is a link to the photos. https://www.flickr.com/photos/150275.../shares/0Uq796
Anyone have a good, easy way to post photos?
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Old 05-02-2017, 10:14 AM   #4
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cool. What does it need?

I use photobucket, mainly because thats where ive always gone, but the interface sucks.
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Old 05-02-2017, 11:01 AM
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Originally Posted by michanecash View Post
cool. What does it need?

I use photobucket, mainly because thats where ive always gone, but the interface sucks.
Well it needs nothing really but its getting a lot! My wife already hates that she ok'ed me getting it.

Thanks for the idea of photobucket, ill give it a try.
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Old 05-02-2017, 11:10 AM
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Here is when I brought her home and put some Hella lights on right away.
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Old 05-02-2017, 11:14 AM
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I hated the rims and tires on her. They were big and just ugly to me to I quickly sold them and bought a set of factory rims off a '15 JK from a guy at work. The only problem was the rims were smaller and the tires were smaller so it sat kinda funny for a bit.
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Old 05-02-2017, 11:18 AM
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In the meantime I had a bit of an electrical issue with my dash lights so I spent an evening troubleshooting and fixing the dash lights. Turns out all the contacts on the back needed cleaned off and I replaced all the bulbs. Now they all work!
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Old 05-02-2017, 11:26 AM
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The next thing I did was look into why it had been running so rich. First thing to fix was the intake. The PO took out all of the air intake and just stuck a cone filter right on top on the throttle body. OK, whatever. well with the vibrations from the engine and just driving around it would sit right on the brake booster and fall off. So that had to go. I looked into buying a factory intake and an aftermarket cold air intake but didnt want to spend the money so I decided to make my own.

I used a 3" piece of PVC pipe, 3" 90 degree, 3" to 2 1/2" reducer and a 3" piece of flex coupling to secure it to the throttle body. I reused the cone filter on the other end. Painted it all black and done. Its not the greatest but it actually works pretty good and looks decent enough for now. Ill end up redesigning it in the near future to include the CVT and canister vent tube like the factory box did.

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Old 05-02-2017, 11:33 AM
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The next thing I did was a tuneup and headlights.
I Replaced the plugs, wires, cap, rotor, belt, idler pulley (PO ran the belt wrong and cut grooves into the pulley), and fixed some vacuum leaks.

The headlights that were in it were HID with red halos. They looked cool but once you turned the lights on you couldnt see the halo. I decided to replace them with blacked out LED headlights and it really changed the entire look of the jeep. I love them and think they are awesome. They put out so much light I rarely use the high beam.
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Old 05-02-2017, 11:40 AM
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Well I ended up getting some new tires from work. They came off a JK that had been traded in. The tread was kinda low for the miles on the jeep so we replaced them. Instead of throwing out the tires I snatched them up and put them on. 315/70r17 BF Goodrich KO. I think they look real good on the factory rims with my lift. Tread is 8/32 so I can get another 10,000 miles out of them for sure, plus they were free!
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Old 05-02-2017, 11:50 AM
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Next thing I did was fix the parking brake because I had none. Turns out there was an open recall still on my Jeep. Can you believe that! An open recall on a 1995 Wrangler, recall had never been done, and you could still get parts! Recall was for the parking brake assembly. Cool! So did the recall at work (I work for a Chrysler dealer btw). Still didnt fix the parking brake issue. Ok no big deal probably needs adjusted and some new shoes.

I decided while I was in there just to replace everything and service the rear diff. Good thing I decided to do that because most of the parts were either broken or missing. SO everything got replaced. Drums, shoes, hardware, wheel cylinder, axle shaft seals, everything! While I had the diff cover off I decided to paint it and the drums. Keep it looking nice and from rusting. The diff looked pretty good, fluid was black but no metal shavings or much flake so that made me happy. filled it up with some free fluid from work and now thats all good to go!
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Old 05-02-2017, 12:03 PM
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And now to get us caught up to today my wife was getting tired of it being dirty and cleaned it for me, inside and out! Doesn't look to bad for a '95 with over 200,000 miles.
Ive also installed mirror relocation brakets because my mirrors fold in every time you close the door. Dont bother with them, they dont work with the doors on, you cant see the mirror on the passenger side. I also replaced the missing driver side fender extension, added D-Rings to the front bumper and to the rear hitch.

Ive got on order a snap repair kit for the top, a new o2 sensor, turn signal lever and switch, clutch pedal pad, clutch kit, flywheel, and a used transmission. The trans is fine other than a few bad syncros so Ill put in the replacement and rebuild the original as a spare. Ive done all this in the last 2 months so I've got a ton of ideas and things I want to do to her so check back and I'll update as I go.
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Old 05-03-2017, 11:16 AM   #14
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Cool. I gotta service my diff. too. be careful with that air intake. If water gets up to it, you could be in for a motor.

looks like a good starting point for a nice build.
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Old 05-03-2017, 11:27 AM   #15
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I also agree on tires and wheels. your new set looks better.
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Old 05-05-2017, 08:05 PM
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Thanks! I need to do the front diff still. Next weekend I'll be putting in the new trans, flushing the transfer case and the new clutch.
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Old 05-09-2017, 09:04 AM
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Ordered a new set of bushings for the front track bar because the jeep was walking all over the road. Got some red Energy Suspension bushings from Autozone for $11 (have a commercial account there). All I have to say is holy crap those things were hard to get in there! I spent probably 3 hours fighting to get the old ones out and the new ones in. However they do look cool and driving the Jeep this morning was so much better! I wasn't all over the road with every little bump. So I ordered another set for the rear track bar and it should be in today so I can get it back on the Jeep. I'll remember to take pictures this time.
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Old 05-19-2017, 04:23 PM
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So this past weekend I was able to get the new trans installed at work with he help of a friend. The old one was a lot worse than I thought it was. The fluid was very milky and mostly water. The flywheel was also in pretty bad shape and needed replaced. So while everything was apart we replaced the rear main seal, flywheel, installed a complete clutch kit, and flushed the transfer case. I was worried about the t-case after seeing the trans but it turned out to be ok other than some dirty fluid. We also checked and greased all the u-joints and cleaned out the old grease in the front slip shaft. A couple of them are going to need replaced along with tie rod ends. Hopefully that will be soon.
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i also installed the new bushings on the rear track bar. I hope to get it installed this weekend if the rain holds off.
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I also took the top completely off for the first time to repair some broken snaps. Turns out the repair kit for my top requires you to cut hols for the replacement snaps. I wasnt too keen on doing this so I repaired what I could for now. I think I'm gonna end up buying a new top in the next few months. What is your opinion on a Spice colored top instead of Black? I think a Spice interior would look better with it but maybe later Ill change that out when I rhino line the interior.

i also got a quote to replace and paint the hood. Over $600!!! The hood apparently has already had some body work done to it and the guy said it would be hard to match it since it was starting to peel off. He would have to sand the entire hod down, redo the old body work and fix the other dents before he could paint it. Im going to try and find another hood myself and may try my hand at some body work and painting on the current hood to save money for other projects.

Speaking of other projects, I'm also hoping to start on another project for the jeep this weekend as well with a friend. We are designing a storage system for the back since I took out the seats and stuff. This will house all my gear for off-road and recovery and also hold some rescue equipment for responding to emergency calls for the fire dept.
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Old 05-22-2017, 06:52 PM
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Quick update. It rained all weekend while I was home so nothing really got done. I did take the steering wheel off to replace the turn signal switch. Turns out it was fine. so i began troubleshooting why my left signal worked fine but wouldn't turn off after turning the wheel and my right signal would turn off if you looked at it funny, hazards worked fine. Then my right stopped working all together. Bad bulb or socket, didn't know. So I went and bought new LED bulbs because the back bulbs were already LED and new led turn signal relay thingys. Guess its a bad socket because half the time it doesn't work, wiggle the bulb it works. Well apparently I messed something up because now nothing works... turn signals don't work at all, neither side will turn off once you turn the wheel, found out the right side marker/turn signal socket and wires are completely missing, hazards don't work... idk! Anybody have any ideas on that please let me know! I guess I have to track down some new sockets for the front and side signals now. YAY!
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Old 05-22-2017, 11:01 PM   #20
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Near and dear machine to me. Had a '95 Rio Grande for 14 years... Kids and a move to Europe (not in that order) has us with a JKUR now, but this is fun to read.

Oh, lose the 3" body lift if no one has mentioned- it's a REALLY bad idea in the YJ. I read a long time ago the tub can crack and the tallest body lift you want to do is 1".

Best of luck and enjoy.
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Old 05-30-2017, 09:34 AM
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Thanks! I have been going back and forth about removing the body lift for some time now. I like how high it sits but I hate it at the same time. I probably like it because its close to hoe high my '08 F350 sat and I miss that truck so much! I think if I can get some guys at work to help me lift the body I'll take it off sometime in the next few weeks. I'll have to order new body mount bushings first.

So I went to install the rear track Bar last night and found out it won't fit with the new bushings. The brackets are too narrow for some reason. The front fit fine. Looks like i"ll have to bend and grind a bit to get it to fit. I also got new Moog u-joints. I was looking into Spicer but couldn't justify the added cost right now. I think the Moog will do fine.

I was able to find some new sockets for the turn signal/parking lights on the front, they should be here this weekend along with new side markers. And my driver door handle broke. So now I have to get in from the passenger side or if the window is down I can reach in and open the door. Order that too and it should be here the weekend also. I did replace the driver side door jam light switch and now both doors turn the light on when open! So I did fix one thing.
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Old 06-04-2017, 04:50 PM
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Some more new parts came in this past week. I got the new door handles installed and can't believe how easy the doors open now. They look good too. The new sockets for the front lights. Turns out the ones I ordered for the front turn/parking lights didn't fit correctly so I went to Autozone and got some ones for a GM that looked almost identical. Wired them in and now I have parking lights. Still don't have turn signals but I still have to wire in the new side markers. I think if I just cut the floating ground and make it a permanent ground it will fix that issue. I found some old wiring diagrams at work in some old maintenance books that show the correct wiring for my YJ with all the wires not just one.

I also found a guy on craigslist selling a Smittybilt Spice soft top. It was brand new, never installed, still in the box. So I scooped it up for $200. Installed it this afternoon before the rain came. Looks great! Found that my factory frame is a bit broken, so I know a guy in Toledo, Ohio, my hometown, who has pretty much any jeep part you can think of. He is going to check and see if he has what I need off a broken or damaged factory frame and let me know. If y'all need any parts give him a shout Z&M Jeeps

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Old 06-18-2017, 08:59 AM
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Quick update. Its rained all week and been hard to get out and do anything. Its suppose to rain again today but I'm going to try to get some things done. I ordered all new snaps for the soft top and a couple pieces that were broken on the frame. Got those on yesterday after work. I also took the old Hella lights off because I got 2 light bars from work for free. Probably 20" or so. I mounted one to the front bumper and I think the other is going on the hood. Ill have to make mounts for it otherwise its been a slow go. Hopefully it will pick back up soon.
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Old 06-28-2017, 02:53 PM
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looks like photobucket has disabled 3rd party hosting for the free accounts. guess i'll have to find a new way to post photos.
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Old 07-02-2017, 09:28 PM   #25
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looks like photobucket has disabled 3rd party hosting for the free accounts. guess i'll have to find a new way to post photos.
Just found this forum and this post, I have a 95 yj 2.5L 5spd as well, 2" susp lift, 1.5" body lift, 116K miles. 32 x 11.5 x 17 BF AT. runs well, needs a make over, would love to see the pics of your build, post here when you have a share site. Thanks

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