Project 1990 Islander YJ, Endless Summer -
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post #1 of 5 Old 04-19-2010, 12:13 PM Thread Starter
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1990 YJ Wrangler 
Join Date: Jan 2010
Location: Mass
Posts: 15
Project 1990 Islander YJ, Endless Summer

Well I have always been a fan of wranglers, even though I drive an FJ, and wanted a project vehicle for the beach. So I picked up a new to me 1990 YJ Islander with 258 I6 and lots of rust which I dubbed project Endless summer since the decals sort of look like the endless summer logo.

Problems: drivers side door handle broken, fuel spikes at full, alternator busted, high idle, radio busted, dash rusted through, driverside floor was replaced with metal screws and aluminum, passenger seat broken and ripped, 4wd not working vac lines destroyed, rust holes on rocker pannel, rust holes where driver seat mounts,rust hole in fender, rust holes where steering box mounts to frame and crossmember where fuel tank mounts rusty.

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post #2 of 5 Old 04-19-2010, 01:55 PM
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1991 YJ Wrangler 
Join Date: Oct 2009
Location: Scranton
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Head to a boneyard and start rummaging for replacement parts, a few of the problems are related, high idle and old vac lines usually come together, the 4wd doesnt work cuz of the vac lines,it has a vac acuator, then grab a used alternator and get ready for alot of body work! you will be happy when its done yjs are fun to have
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post #3 of 5 Old 04-19-2010, 10:21 PM Thread Starter
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1990 YJ Wrangler 
Join Date: Jan 2010
Location: Mass
Posts: 15
Installed new Alternator, now the blinkers work and the fuel gauge works when I hit it, then it spikes again, I look at the wiring when I get the dash off,

Starting to figgure out why people hate torx...
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post #4 of 5 Old 05-20-2010, 09:57 PM Thread Starter
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1990 YJ Wrangler 
Join Date: Jan 2010
Location: Mass
Posts: 15
Just got done installing the new dash, the disassembly took two weeks while the reassembly took a few hours not including rust repair and paint, but wait now the windshield won't fold all the way back up, I did install a new windshield cowl seal but even before that it wasn't going all the way back up, I have it withing three inches of the roll bars after using a ratchet strap but the ratchet broke and now I'm stuck. On top of that I stripped another torx bit on the hold down bracket so I cant fold it back down, my screw extractors are useless cause apparently the bolts are made out diamonds and eat drill bits for breakfast, so what now?
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post #5 of 5 Old 05-20-2010, 10:07 PM
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1991 YJ Wrangler 
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Location: Orlando, FL
Posts: 2,198
The new cowl seal always makes it hard to position the windshield back where it was. You can adjust the cross bars to make them longer if you want too, or just bolt the windshield down with the tabs and not the cross bars for now.

My windhield cowl seal flattened out a little after a few weeks then I was able to tighten things back up again easy.


/l , [____],
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