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Unread 09-17-2012, 07:43 PM   #1
jeep63
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91 YJ - purchased new, sold, just bought it back

I purchased my first jeep in 1991. It was a YJ w/2.5L. Just a basic, simple Jeep. I built it up over a number of years until it was sitting on 35s w/4.88s, 4:1 xfer case, 6" of lift, full cage, winch, Locked Front and Rear, etc... I last wheeled it hard in July of 2004. On that trip I finally broke a rear shaft in the D35.

Here is my son posing with the Jeep after we got off the trail...



I purchased a D44 from a Cherokee and was getting ready to install that when a series of unfortunate circumstances led me to the 89 YJ I have today. I pulled everything off the 91 that was worth anything. I either sold the stuff or moved it to the 89. I then bolted stock stuff back on the 91 from the bone yard and craigslist. I sold the 91 in the Summer of 2005 to my BIL.

For reference, here is my 89 with my son inside.



Skip forward to this month...

I find the 91 Jeep in my MIL's garage where it has been sitting for 2 years. It has two flat front tires, a questionable clutch, and the tail pipe is sitting on the floor.

I bought it back and towed it home. My son and I are hoping to restore it and drive it around.

tonight, after I pulled the coil wire and cranked the motor a few times to build up oil pressure; I got it to start without issue.

We were both jumping around high-fiving each other; it was a cool moment.

Now, I am going to drain all the fluids, change the plugs, wires, cap, rotor, fuel filter, and install a new clutch master cylinder which I hope cures the clutch issue. I don't relish dropping the tranny to change the slave.

I'll try to keep this as my build thread and post up some newer pics of the 91 Jeep.

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Unread 09-17-2012, 08:52 PM   #2
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Cool! Hope all goes well!
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Unread 10-04-2012, 06:24 AM   #3
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We started tearing it all apart now. I plan to do as much of a frame on restoration as possible. I have dropped the xfer case skid and the gas tank one. The skid plates need replacing, I found a gas tank one, but I'm still searching for a xfer case one. The frame is solid, so I will just paint it with POR15, and the Chassis coat on top. I am working on taking the axles and springs off to paint them too. Here are some shots thus far...





My son taking off the shock... (Yes, I got on him about not wearing his safety glasses)


I'm hunting for a windshield frame, tailgate, and passenger front fender. I am still debating trying to paint it using foam rollers or use money he and I have been saving for the paint job.

The xfer case is leaking, so I need to take that off and fix the leak. I am trying not to let this snowball into a full blow restoration. Just a mild one...
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Unread 10-04-2012, 07:18 AM   #4
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Looks awesome nice looking rigs you got there.. Definetly subscribed!
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where'd all my money go? oh yah i bought a jeep
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Unread 10-12-2012, 04:47 AM   #5
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Finally have one of the rear springs off. The spring hanger eye bolts are seized to the bushing sleeve. I had to cut the ends off and pry the spring out of the hanger. The springs are not too bad, but I am considering going OME or BDS for a small 2" lift. I would prefer no lift, but if I get new springs I might as well go for better riding ones than OE.

I got the old 2" body lift off. It was not too bad. I used anti-seize all those years ago and only one gave me a fit and that is because the bolt was stuck to the sleeve and would not "drop" out. I am replacing all of it with a 1" poly body lift that comes with new bushings, etc...

I am still searching for a new xfer case skid... These stock skids are hard to find. Quadratec sells OE replacements, so I may have to go there. So far everyone I call with a parts jeep has the same story... "Skid is shot because holes are rusted out". I considered a UCF no body lift skid. I have one of their ultra high clearance ones on my 89, but there are no drain holes and it makes a huge mess when you drain the tranny/xfer case. Plus that is $100.00 more than the Q'tec OE replacement one. This is not going to be an offroad jeep. It will be a run around town/beach one.

I only get about 1.5 hours a night to work on this; between school, scouts, and sports I am running around so much that this project is going very slowly.
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Unread 10-12-2012, 08:17 PM   #6
140mower
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[I have one of their ultra high clearance ones on my 89, but there are no drain holes and it makes a huge mess when you drain the tranny/xfer case.]


Just an idea, but on my excavator and skidsteer, the manufacturer put short hydraulic lines on the drains just long enough to clear the obstacles, capped them and tucked them away until needed. Works well enough that Ive adopted the idea when ever I've encountered this problem.

Don
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Unread 10-12-2012, 08:21 PM   #7
andrew2641
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Good to get the kids involved. Good luck with the restore.

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Unread 10-15-2012, 04:48 AM   #8
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Quote:
Originally Posted by 140mower View Post
[I have one of their ultra high clearance ones on my 89, but there are no drain holes and it makes a huge mess when you drain the tranny/xfer case.]


Just an idea, but on my excavator and skidsteer, the manufacturer put short hydraulic lines on the drains just long enough to clear the obstacles, capped them and tucked them away until needed. Works well enough that Ive adopted the idea when ever I've encountered this problem.

Don
Thanks for the tip Don
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Unread 10-21-2012, 03:41 AM   #9
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I have the rear axle out and mostly cleaned up. Brake lines were seized to the nut, not the wheel cylinders. The lines were so rusty, I'll bet half the line thickness was gone! Time to source near rear axle hard lines. Pull the xfer case to fix a leak where the halves meet. I toyed with the idea of an SYE, but it does not make sense for what I plan to do.

My wife thinks it looks squatty without a lift, so I"m getting OME springs/shocks to give it a great ride. Lift height is not a goal, nor is off-road. I'll just be running 30s to give it a nice look.

Pulling the front axle today to clean and prep for paint. Hopefully, I can get started cleaning the frame so I can paint next weekend.

I need to pull the tranny during the week so I can replace the clutch/slave. Don't have pics uploaded yet...
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Unread 10-21-2012, 06:40 AM   #10
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What a cool story, having your 'old' Jeep back and being able to share the build with your son!
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[B]Comments and advice welcome:[/B] [URL="http://www.jeepforum.com/forum/f22/jtbergers-87-yj-build-my-first-car-15-years-later-1424836/#post14265022"][B]JTBerger's '87 YJ Build - My first car... 15 years later.[/B][/URL]
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Unread 10-21-2012, 07:48 AM   #11
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I wrapped up for this morning. I have the front axle pulled now and the xfer case is spilt, cleaned out and ready to be sealed back up. Everything is tight in there, so I just had a small leak.

Hopefully later today I can get the front axle cleaned up and start cleaning the frame to paint.



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Unread 10-29-2012, 05:25 AM   #12
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I pull the transmission yesterday. It went very smooth, and I credit my transmission jack adapter purchase. It was a great addition to my tool collection.

I checked out the clutch and it turns out the clutch is in fantastic shape for a 12 year old clutch. It is a center force clutch that I installed in 98. The clutch problem was coming from the slave. The pin holding the slave to the front bearing retainer plate was gone, so the slave was "floating" so to speak. The slave itself appears fine. The flywheel looks great too. At first I was just going to put a new pin in and call it a day, but I decided to replace the clutch since I already purchased a Luk clutch & slave kit. I am keeping the original clutch & slave as a backup should something happen in the future.

I want to clean up the tranny and bell housing before installing the slave, and putting it all back together. What is the best way? I have been using simple green and a scrub brush on the bellhousing and I got the worst off, but I want it clean. Is a car wash a good idea? Use their degreaser and power wand?

I hope to begin cleaning the frame this week to prep for POR15. Then I will order my OME suspension. Any vendor recommendations for OME?

I also have a question about replacing the rear main and oil pan seals. Since the only thing left in the jeep is the motor I don't have a way to support it and remove the oil pan, so my question is. Are the motor mounts enough the hold the motor while I replace the rear main and oil pan seals? Or, should I wait until I have everything back in and then support it by the transmission when replacing these seals?
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Unread 10-29-2012, 05:59 AM   #13
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That YJ looks like it is in good shape! I look forward to watching the progress on this "mild" build. Good luck!
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Unread 10-29-2012, 06:14 AM   #14
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Quote:
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That YJ looks like it is in good shape! I look forward to watching the progress on this "mild" build. Good luck!
Thanks.

Fortunately for me it was always kept in a garage, even after I sold it. Only some very mild surface rust on the front fenders.
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Unread 10-31-2012, 10:48 AM   #15
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So...

I noticed these cracks at the rear of the transmission. You can clearly see the one at 6:00, and the one at 3:00 is there, but looks faint. There are also two smaller ones close to 7:00. They look bad. Any chance they are just "from the casting" process?

The transmission has 225,000 miles on it, so its time may have come.

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