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Unread 03-23-2012, 04:31 PM   #1
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
My 1995 Red 2.5L YJ Rebuild

OK Guys & Dolls, here's my attempt at a rebuild thread...

I am not doing a frame-off restoration, like some people.
I am not doing my work in a fully stocked shop, like some people.
I am not doing a unlimited budget rebuild/upgrade, like some people either.

But what I AM doing is a rebuild to get my beloved YJ back on the road & safely as my daily driver. I bought it in 2000 from one of those Buy Here/Pay Here places in Jacksonville, FL that had it up on their show rack & I saw it coming home from the beach one day. The PO was a NJ resident that towed it from NJ to FL & back every year behind their RV. Bought it on the spot. Factory air, 50k miles on the dash & clean as it could be...

I did very little to it other than drive it until I moved to SC. The interstate driving from FL to SC for our relocation killed the little 2.5L. It has sat for a few years until I could muster up the courage to attempt the rebuild.

The pic below is from the last time it was drivable.

MORE TO COME

20110521.jpg  
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'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 04:40 PM   #2
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
Here's the 32*11.50*15's that are going back on it.
They have sat for a year & I was scared they were flat on one side.
I pumped them back up to 35psi & they rounded right back out.
Will drive them for a week or so to see if they are in need of replacement...
20120320095923.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 04:42 PM   #3
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
And here's most of the stuff that's going into it & what's being replaced...
20120320095933.jpg   20120320100310.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 04:47 PM   #4
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
I love my wifey ! ! !

And this is the reason that I'm attempting all this.
My wife bought me a new air compressor & a new set of air tools for an early birthday present.
AND my Brother-In-Law is coming down from TN next week for us to tackle the engine work. (He's a lifetime mechanic)
20120320100208.jpg   470409_3516737518923_1286521153_33477964_1090810582_o.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 04:56 PM   #5
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
These I'm most embarrassed of. I've let it sit under an oak tree & used it as a storage unit for parts for more than a year...
20120320095945.jpg   20120320100238.jpg   20120320100220.jpg   20120320100248.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 05:10 PM   #6
Spazze
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1995 YJ Wrangler 
 
Join Date: Mar 2012
Location: Goodwin, South Dakota
Posts: 59
Looks nice. Good luck w/ the work.
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Unread 03-23-2012, 05:17 PM   #7
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
Here's the start to finish on the rear brakes.
Yes, those were cob webs embedding to the drums.
I took a wire brush & an air gun to everything to clean it up.
Rinsed it all down with non-chlorinated brake cleaner & coated everything with Rustoleum Rust Converter.
New shoes (replaced for FREE under lifetime warranty) & put it all back together...
20120320095958.jpg   20120320115712.jpg   20120320122837.jpg   20120320121445.jpg   20120320142624.jpg  

20120320115903.jpg   20120320143526.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 05:31 PM   #8
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
Front Brakes

Didn't get a chance to take a pic of the condition of the front rotors & calipers. I was too much in SHOCK.
There was a bird's nest inside one rotor & there was a dead mouse stuck inside the other caliper.

But here's the before & after atleast...

I took the rotors to have them turned. Just had very light surface rust.
New pads courtesy of another lifetime warranty replacement.
Again, wire brushed & air gun'd the debris away & a light coating of Rust Converter...
20120321093110.jpg   20120321133512.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 05:37 PM   #9
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
Shocks

This is an easy one, but I took the pics...
so you shall see it...

And yes, that is a Chrysler emblem (A.K.A. OEM shocks). Yeah, they were shot. 17 years old & 130K miles... DONE

And before I get flamed for my shock choice, they are the Pro-Series Gabriel's. I chose them based on the price & the warranty. I paid $30 each for them & am getting a $20 rebate per shock...
20120321131837.jpg   20120321131914.jpg   20120321131856.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 03-23-2012, 06:14 PM   #10
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
Rear Brake Light Relocation

OK, so this isn't a primary part of my rebuild, but it's SO freakin' easy & cheap, WHY would ANYONE buy a kit to do this...

$9.63 in hardware from ACE Hardware & no my Rear Brake Light is 1.25" higher to clear my spare tire...
And I don't have to look at those Torx bolts anymore.

20/20 Hindsight, I should've gotten 4 more washers to have between the bolt head & brake light bracket...
20120323184615.jpg   20120323184624.jpg   20120323184738.jpg   20120323184855.jpg   20120323185854.jpg  

20120323185905.jpg  
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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Unread 04-01-2012, 01:43 PM   #11
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
And in the More to Come category...

OK, I just discovered that I suck at doing a build thread while I'm working with someone else. I did not manage to take a SINGLE pic while were were dismantling the donor engine or while installing ANY parts into my Jeep. I was too focused on the tasks at hand...

But I can tell you this, the process went SUPER smoothly. We had the donor broken down & the majority of the parts back in my Jeep within a day.

I've got new shocks, new brakes, a professionally rebuilt head, a properly wired & mounted electric fan now (& no Clutch Fan), & we even fixed a few leaks along the way.


I still need to drain & flush the old oils. drain & flush the cooling system, finish changing out the differential fluids, and check into the 5th gear repair (I still barely have a 5th, but it won't be long by the sound of it), check & replace all the steering hardware as needed (tie rods look bad) & fix the A/C (I have a replacement compressor & clutch in the box waiting, but my blower assembly went out awhile back)...

Will take a few pics this afternoon of what we actually did, and try to document any more work as I get it done...
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
JimmyFW1 is offline   Reply With Quote Quick reply to this message
Unread 04-01-2012, 02:03 PM   #12
crackedcornish
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1988 YJ Wrangler 
 
Join Date: Feb 2012
Location: Lake Hopatcong, NJ
Posts: 1,117
of course you know you shouldn't use compressed air to clean old brake parts, because of the possible danger of putting asbestos dust into the air that you're breathing...you did know that, right?
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Unread 04-07-2012, 11:03 AM   #13
JimmyFW1
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1995 YJ Wrangler 
 
Join Date: Aug 2003
Location: Walterboro, SC
Posts: 131
Quote:
Originally Posted by crackedcornish View Post
of course you know you shouldn't use compressed air to clean old brake parts, because of the possible danger of putting asbestos dust into the air that you're breathing...you did know that, right?
Good Thing I had ceramic pads on there then... I ordered them years ago when I was a PSM @ Auto Zone, since I got them at 20% off for being a manager...

But I do appreciate you bring up that point. People need to be careful. I wasn't, and I"m not always.
But like I said, Thank You. Hopefully someone else will read this & think about taking the precaution...
__________________
'95 Red YJ, 4-Banger... Nothing special yet, but stay tuned: More to come...
'04 Black KJ Limited, 3.7L, 17" Factory Chrome, pretty much bone stock, bought to be a family carrier, and has become a problematic BEE-YOTCH as of late...
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