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Old 06-09-2019, 11:55 AM
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Bump Stop Build

My friend has a name for everything he owns. His riding lawnmower is named Snippy, Bubbles is his boat, Bones is his FJ Toy, Papa Smurf is his 80 something Toyota, and The Wolf is his F250.so when I bought my 89 YJ early last year he asked what I was going to name it. It rode like a covered wagon with its tired old stock leaf springs so I felt like I was a bump stop so that was its new name, naturally.

On the trailer getting her home.

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Old 06-09-2019, 12:03 PM
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I bought a donor vehicle that had an engine fire from the same seller a couple weeks later. Useful parts included 2.5” lift springs, 4:56 gears, hardtop and doors, AX15, NP231, and wheels.

Not bad for $1500. I sold the chassis, tub, windshield frame, and roller axles and tires for $600 because I didn’t have time and space to part it out so I got a lot of useful parts for $900.
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Old 06-09-2019, 12:13 PM
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First order of business was to swap the axles and springs. Time for a working party!
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Old 06-09-2019, 12:16 PM
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I didn’t like the tan dash so I took that apart and painted it. Found some minor rust and cleaned that up a bit. Can’t find the after photos.
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Old 06-09-2019, 12:21 PM
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That was it for a while. I ran it for a few hundred miles on the old tired, oil burning 4.2L.

As far as I could tell I had one good cylinder, three with bad rings, and 2 with bad valves, but old Smokey still ran so I was going to run it till it stopped. It wasn’t the engine that quit though. Never seen a transfer case housing split open before.
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Old 06-09-2019, 12:29 PM
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I rebuilt the donor NP231 and installed a SYE and installed the donor AX15 since it was recently rebuilt before the donor caught fire and the current one was grinding between gears. Turns out the original AX15 might have been running the original gear oil! Sludge!

Since I need a new driveline I decided to install a better lift and ordered a 4” RE lift and boomerang shackles. I pulled the axles out and cleaned them up and painted them. Overall, I’m really happy with the lift stance, but I think I’ll be taking the 2” body lift off since I’ll be sticking it’s 33’s on the D30 and D35 axles.

I had a bad axle seal so I replaced the rear seals, bearings, and brakes. So now everything from the shackles down is brand new.
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Old 06-09-2019, 12:33 PM
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I ran out of things to do so I cleaned up the fire damage on the hardtop and repaired the door cracks before paint prepping them.
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Old 06-09-2019, 12:34 PM
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She sits pretty tall for the 33’s, but looking good!
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Old 06-09-2019, 04:41 PM
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Next order of business was to rebuild the 4.2. I learned about the 4.0 head swap for better HP, but I found a complete 4.0, with harness, and ECU for cheaper than I could build the 4.2. So oout with the old and in with the newer.
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Old 06-09-2019, 04:44 PM
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She’s not quite ready for the new power plant. I think I’ll be upgrading the motor mounts to Brown Dog Mounts since the passenger side mount broke a bolt in the block. I should be able to order those in a bit, but in the meantime I figured it’s a good excuse to clean up the engine bay.
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Old 06-09-2019, 04:49 PM
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Probably could have used a couple stitches here. I was pulling the clutch off the newer motor and like a dummy I took the top bolt out before the bottom. Once I popped the bottom bolt out the housing came down and caught my knuckle on an edge. Took it down to the tendon or bone! I don’t know which, but something white was peeking out when I opened it up.
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Old 06-09-2019, 04:53 PM
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So, the to do list:
Engine mounts
Install Engine
Figure out the wiring between a Renix and an OBDI
Fuel Delivery
Order drive line for the rear
Replace u joints on front drive line
Drive it for a bit/ and go hunting in November
Build cage
Build rear bumper/ tire carrier
Build front bumper
Paint it
Fix it
Drive it
Fix it
Drive it
Fix it...
Drive it
Hope to have enough left to retire!
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Old 06-10-2019, 05:53 AM
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Score! I just ordered Brown Dog, left and right side engine mounts with a 1" Engine lift (Super Kit). The subtotal was $354, but I saw a coupon code field. A quick google search brought up a code that knocked it down to $319 and saved me $35.

If you see a field for coupon code, always do a search. You never know.
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Old 06-14-2019, 08:04 AM
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Took the new 4.0 to the car wash and cleaned it up a bit. Just waiting for the brown dog motor mounts to come so I can get it installed. I’ll be taking the flywheel to get it resurfaced today.

Can’t wait to get moving!
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Old 06-14-2019, 09:06 AM   #15
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Man.... that is a lot of progress for 5 days.
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Old 06-14-2019, 09:21 AM
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Man.... that is a lot of progress for 5 days. [IMG class=inlineimg]https://www.wranglerforum.com/../images/smilies/smile.gif[/IMG]
it’s been a few weeks, just getting the thread caught up.

Got my brown dog mounts yesterday. That was fast!
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Old 06-14-2019, 09:37 AM
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Can’t wait to get the motor mounted! These mounts are quality! Great packaging too!

Taking the flywheel to get resurfaced today. Then clutch install and mount the engine.

I have to try to get to Upull in a couple weeks to scrounge for a few parts and possibly a fuel tank with an internal pump. I’ll be camping next week so it’ll have to wait!
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Old 06-14-2019, 01:14 PM
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Easy install. From three to seven mount points on the driver’s side and from two (one was broke and destroyed the boss) to seven on the passengers side. Flywheel is at the machine shop. Looking forward to getting this installed and wired up!
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Old 07-12-2019, 10:10 PM
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Further down the rabbit hole I go. The Renix system is done. Pulled engine and dash harness. Have a dash harness from a 95 coming soon.
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Old 07-13-2019, 11:45 AM
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It doesn’t look there is much activity on these boards, but if anyone has 92-95 YJ I have a question. My donor harness was cut where it goes into the firewall. I need to know where that harness went inside the cab.

My 89 went to the ECM, I’m assuming the 92-95 went to the instrument cluster.
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Old 07-15-2019, 12:27 PM   #21
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Those wires all look too big for just signal wires to a gauge. My Jeep is older as well so I can't be certain. Maybe some of them are gauge. If I remember correctly oil pressure is green and white and tach is purple.
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Old 07-16-2019, 02:42 PM
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Those wires all look too big for just signal wires to a gauge. My Jeep is older as well so I can't be certain. Maybe some of them are gauge. If I remember correctly oil pressure is green and white and tach is purple.
Thanks
This goes to the 10 pin connector, which I believe connects the body wiring harness. The 4 extra wires go to the OBDI diagnostic port. I believe the 10 pin powers the rear lights and hardtop options. I should know in a few days when I get my in dash harness in the mail.
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Old 08-19-2019, 02:04 PM
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I've made a ton of progress over the last couple weeks. All that is left for the drivetrain is the front driveshaft. I got my TW Driveshaft installed with the 10* shims on the rear axle.

I've got my fuel lines nearly done and replaced all the hose clamps with EFI rated hose clamps. I have my fuel filter and fittings int he mail and plan to tackle that on Friday.

Engine is almost ready to crank up. Coolant in, PS steering complete and full, Airbox mounted up. ECM mounted and routed. PDC mounted. I have power where I need it and headlights work. Waiting for turn signals.

I have my Mil Spec battery connectors and will be putting together battery cables and hook up starter on Friday. If all goes as planned I should be test cranking the motor on Friday afternoon.

Still need to:
Wire in new body harness
Wire stereo
Add transmission fluid
Bleed clutch and brakes
... and thats pretty much it before a good clean up and start the body work to prep for paint. I may primer it for the winter so I can build my cage, bumpers, and tire carrier without worrying about the paint getting scratched.
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Old 08-19-2019, 03:04 PM
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This was what I came up with. It is canted instead of verticle so I drilled drain holes on the bottom corners to allow any water that gets trapped in the case to drain.
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Old 08-23-2019, 10:48 PM
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Major milestone! Engine starts and runs strong!

Finished up my fuel filter and Mil Spec Battery terminals and cables.
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Old 08-25-2019, 01:26 AM   #26
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nice project!!!!
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Old 08-25-2019, 01:47 AM   #27
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Looking good!
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Old 08-26-2019, 01:42 PM
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Thanks! I know its pretty basic for the most part, but its been fun. I'm ready to drive this thing though. Hoping to be on the road before the cool down so I can enjoy the top off for a little while.

I still need to install the body wiring harness and get the rear connected to the dash harness, figure out how to mount the 91-95 brake light switch since it is different from the 89, and put the hardware in my new tailgate and mount the spare.

Once I'm able to drive it I'll start sanding the body and getting it prepped for primer. I'll likely keep it primed for Winter so I can work on fabricating the cage and bumpers and paint it all in the Spring.
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Old 08-26-2019, 09:48 PM   #29
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Sounds like a good plan
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Old 09-06-2019, 08:32 AM
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