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Old 11-30-2017, 11:15 PM
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Project "Rusty" 95 YJ 4.0, Auto build

Thanks for the add.
I just picked up a 95 YJ in April that had been sitting for a year as the previous owner had replaced it with a new car and never got around to fixing it up.

I owned a 94 4.0 auto YJ back in 98 for a year that was essentially stock and didn't need any wrenching on it.

I knew this one was going to need a ps pump and new front calipers, rotors and pads right away. Then there was that nasty looking frame near the right rear shackle that I figured wouldn't like a hammer tapping on it..I was correct it didnt.

It ran good, the body wasn't too bad nor was the interior...a good start and the price was negotiated down fast once I extolled the virtues of frame rust.

It had aftermarket bumpers, a 3"body and 2.5" suspension lift...some old jeep rims with worn tires had been thrown on it, apparently his Dad took the nice ones.

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Old 11-30-2017, 11:35 PM
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More frame pics...still seemed pretty solid albeit not pretty.

The jeep came with a new set of energy suspension poly body mounts too.
I see why the previous owner only had replaced 2 of them and hacked the floor up to do it and just left holes!!!! Yaaayyy more work ahead.

I just want it safe to drive first.
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Old 11-30-2017, 11:50 PM
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Picked up a set of 5 Wrangler Sahara rims and tires and ordered some 2" wheel adapters.

Looks better than it did. Now at least the tires match and are roadworthy
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Old 12-05-2017, 10:44 AM   #4
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The body mounts on these things are horrendous to work on. Especially for a Jeep from the salt belt... I had to cut a hole in the floor over everyone one of my mounts as the bolts were literally rusted to half their original diameter and just snapped off with the least amount of pressure. I just made sheet metal covers for the holes and attached them with #6 self tapping screws so they are there if I ever need to get to them again. Good luck on your project.
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Old 12-06-2017, 01:18 AM   #5
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Tell us a little more about the body mounts 93YJFan. How did you handle the new mounts? Bolt washer nuts? Any pictures of your covers?
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Old 12-13-2017, 08:49 AM   #6
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Sorry for the late reply just saw this today. I basically used a 2 1/2" hole saw over every mount bolt to provide access. My mount bolts were so rusted they just snapped with the slightest pressure from the breaker bar. They had literally rusted to less then half there original diameter. There is a metal cage for lack of a better word, that holds the threaded metal plates in place that act as nuts for the body bolts. I just used a long chisel and pried those out of the way and drove the broken bolts up through the hole with a long punch.

When I went to put the new mounts on I just used new bolts and large flat washers with nylock nuts to hold everything together. I then fabricated some covers out of a scrap piece of fender material I had left over from rust repair and held them in place with #6 self tapping screws. I also applied a little black silicone to the back of the cover to provide a better water seal.

I have attached a picture of the condition of my mounts, and you can see what the threaded plates look like and a picture of the hole I drilled. Since it was a little off I had to pry up the edge a bit to get the old bolt out. I then cleaned it up and made a round cover to go over the hole. It's not an exact science but you should get the idea. I also used anti-seize on all the hardware when I reassembled it.
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Old 12-14-2017, 06:20 AM   #7
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Thanks. Was it a body lift and did you keep it or change it? PO of mine installed a 3" that I want to eliminate but am intimidated by the project. Particularly lowering the body. Happy Holidays
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Old 12-22-2017, 10:37 AM   #8
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Wow I need to check my threads that I contribute to more often. No there was no body lift on it when I bought it, just a screwy shackle lift. I replaced all the body mounts with factory style mounts and new bolts. Taking the body lift off may not be to bad, as the bolts won't be 25 years old. Just loosen everything and then jack up one side at a time leaving the bolts on the other side installed and remove the 3" lift pucks and install new bushings and bolts then lower it and do the other side.

Here is the kit I used as it came with all new hardware also:

https://www.quadratec.com/products/55008_0008_07.htm

Good luck on your project. PM me if you have any other questions as I will see that sooner.
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Old 12-23-2017, 05:29 AM   #9
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No worries, I haven't started yet. Just trying to gather enough info to feel reasonably comfortable before I dive in. Thanks. Happy Holidays

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