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Spartan Locker Promo Running now @ ROCKRIDGE 4WD plus FREEG2 Disc Brake Conversion Kit for Jeep Wrangler YJ TJ LJ ChTJ Wrangler 4" Rough Country Suspension Lift Kits in

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Unread 11-07-2014, 12:13 AM   #1
petertom13
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1995 YJ Wrangler 
 
Join Date: Aug 2014
Location: Coon Rapids, Iowa
Posts: 137
"Herky"

So, guess I'll start it off with a picture, first night with my new DD at work.


1995 YJ, 4.0 inline six, 5 speed, 58,900 miles, and a salvaged title. Picked it up for $5400, and it looks to be in great shape for being a 19 year old Jeep in Iowa. Minor rust spots showing underneath the flares, underside looks clean. Dana 30 front, D35 rear with 3.07 gears, riding on 33" BFG AT, and Eagle Alloy 15x10.5 rims. Immediate plans only involved minor exterior changes, some cosmetic items.

The future was so bright... fast forward about 3 months... sitting on jack stands in my garage currently as I learn to fix things for myself. I try a lot of things, and depending on who you ask I have a varied success rate at how well they turn out. Needless to say, I can change oil, tires, and brakes. I know that lefty is loosey and righty is tighty, I can identify most tools, but I'm far from handy when it comes to vehicle repairs and work. So all of this build I'm going to try to do myself, and with an EXTREMELY small budget. I have a wife, four kids, two dogs, and a 100 year old house that I'm working on at the same time. Our money goes to the house, not the Jeep.

I will be relying on this forum, generosity of people, my bartering skills, and just a sheer desire to not piss my wife off while I work to improve this 'thing'.

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'95 YJ "Herky", 4.0 I6, D30 Front, D35 Rear, 3.07 gear, 33" BFG AT
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Unread 11-07-2014, 12:27 AM   #2
petertom13
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Jack Stands??

So, three months into ownership, now it's on jack stands in my garage. Started with some small noises, thought rocks in tires?? loose brakes?? Not real sure what was going on, continued to drive, did some mild wheeling, got it muddy a couple times, just some innocent fun. Then the **** started getting serious, vibrations developed, noises from the clutch/tranny/transfer. Used the forum to diagnose, and decided to do some fluid change and u joints.

Rear U joint


Front U joint


Changed out tranny fluid, transfer case, and engine oil. No improvement. Decided to get dirty, borrowed a DD from a friend and got the garage stall cleared out and ready for some work.

Pulled front and rear driveshafts...




Notice the yellow writing on the front driveshaft and same yellow marking on the rear? Seems like I've seen that before somewhere....junk yards. So this is where I'm at right now, trying to diagnose what I'm dealing with.
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'95 YJ "Herky", 4.0 I6, D30 Front, D35 Rear, 3.07 gear, 33" BFG AT
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Unread 11-07-2014, 12:40 AM   #3
petertom13
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So, gotta give a shot out to the guys in the YJ forum, have been very helpful and very patient with me being an auto idiot and trying to figure things out without them actually having to draw me a picture. Big shot out to Goob, fellow Iowan has been very helpful, and I don't think I would be attempting any of this if it wasn't for the incouragement and support.

U joints are out, two different sizes in the rear axle??


One of the caps was a dusty, rusty, dried up pile of nothing inside...


Haven't gotten replacement U joints in, but I don't even know that I have the proper drivetrain yet, going to rely on the /f12 to get me to where I need to be.

did make myself a handy 'tool' to remove the u joints with a BFH..

1/2 steel pad with 1.25 hole, made for a nice cavity to drive the joint into, worked better with BFH than with clamp.

wanting to drop skid plate, and tear into tc, tranny, and clutch...skid plate is bolted up with rusty bolts that require allen wrench to remove...
not working..


still not working...

all those are busted as well.

Goob pointed out that my slip yolk looks suspicious...not symmetrical?


I'm going to look at that tonight after work, and get the sawzall out for the skid plate bolts. It's coming off!!!
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'95 YJ "Herky", 4.0 I6, D30 Front, D35 Rear, 3.07 gear, 33" BFG AT
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Unread 11-07-2014, 12:41 PM   #4
petertom13
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Well it took a cut off blade, BFH, and a sawzall but the skid plate is down.


Six bolts with six spacers, and this is all that survived


Finished pulling the diamond plate and fender flares off, got a good look upcoming work.





Well, time to start looking into other JF members fender cuts, see what kind of highline or other design I can decide on. Enough for this day. Attack the transfer case, tranny, and clutch another day.
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'95 YJ "Herky", 4.0 I6, D30 Front, D35 Rear, 3.07 gear, 33" BFG AT
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Unread 11-07-2014, 05:15 PM   #5
amp713
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F12 has an amazing set of people to guide along the way! Ill do my best to create no issues here hahahahaha
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Unread 11-09-2014, 11:26 AM   #6
lovett86
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cool project
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its a rusty one

http://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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Unread 11-09-2014, 12:00 PM   #7
AZdEvilYJ
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Your sales pitch sold me! Sub'd
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Unread 11-09-2014, 12:35 PM   #8
Hawaii5O
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Looks like you have some work ahead of you. I had the same issue with my skid plate. Had to weld nuts to the heads to get them out.
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Unread 11-09-2014, 01:08 PM   #9
awinski
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sheesh man that is more than most would deal with. props for doing it all yourself! crawled
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Unread 11-10-2014, 10:14 AM   #10
petertom13
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1995 YJ Wrangler 
 
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So I've watched a couple videos, still not 100% confident on the transfer case removal, watch a couple more tonight, give it a shot tomorrow morning. I did decide to empty out the tub to see if there was any work in there.

Looking good, very happy with this.




The rear fenders are good too, just snapped these pictures before I pulled the remainder of the carpet out. There are a lot of holes, not sure if I'll just put bolts in the majority of them, or try to find rubber plugs. PO had old sink stoppers in the drain holes in the floorboards, LOL I suppose it worked and saved them some money, but I'll probably try to find a better fit that sits flat to the floorboard. One of the stopper still had the metal ring on the stopper, surprised he/she took the time to take the chain off of it.

I did find this in the engine compartment, it appears to be coming through the firewall on the driver's side, then comes out of main wiring bundle on the passenger side of the engine bay and is hanging freely at the back of the motor. Anyone know what it is?


If there are any 'secrets' I need to know about dropping the transfer case, feel free to share, like I said I'll watch some more videos online and browse the forum for some good picture heavy threads.
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'95 YJ "Herky", 4.0 I6, D30 Front, D35 Rear, 3.07 gear, 33" BFG AT
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Unread 11-10-2014, 11:00 AM   #11
amp713
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PB blast/WD40 the bolts for a few days before hand on any bolt removal and it will save you a lot of trouble! I cant speak for that one exaclty but my YJ has 2 of those that are unhooked on the firewall and have nothing going to them. Seems to be common on a lot of jeeps though. Like a one harness fits all and we dont have the piece that needed that wiring
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I like my YJ how I like my whiskey, on the rocks with just a touch of color!

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Unread 11-10-2014, 09:12 PM   #12
dander88
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Quote:
Originally Posted by petertom13 View Post
So I've watched a couple videos, still not 100% confident on the transfer case removal, watch a couple more tonight, give it a shot tomorrow morning. I did decide to empty out the tub to see if there was any work in there.

Looking good, very happy with this.




The rear fenders are good too, just snapped these pictures before I pulled the remainder of the carpet out. There are a lot of holes, not sure if I'll just put bolts in the majority of them, or try to find rubber plugs. PO had old sink stoppers in the drain holes in the floorboards, LOL I suppose it worked and saved them some money, but I'll probably try to find a better fit that sits flat to the floorboard. One of the stopper still had the metal ring on the stopper, surprised he/she took the time to take the chain off of it.

I did find this in the engine compartment, it appears to be coming through the firewall on the driver's side, then comes out of main wiring bundle on the passenger side of the engine bay and is hanging freely at the back of the motor. Anyone know what it is?


If there are any 'secrets' I need to know about dropping the transfer case, feel free to share, like I said I'll watch some more videos online and browse the forum for some good picture heavy threads.
Can you follow the wires? Its a relay harness or sorts.
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Unread 11-12-2014, 01:30 PM   #13
petertom13
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So, a little update, haven't gotten much done in the past few days, the wife has been working during the day so I've been watching daycare kids, and the only time I get a chance to work on the Jeep is when I get off of work at midnight or later.

Now I know, transfer case removal is a minor job for most, but for me it has been the pinnacle so far. I was very reluctant to try, but I went for it, and it wasn't as bad as I thought, thanks to the JF and all it's members. Now that I have it out, time to research what to take apart on it, and see if I can identify any parts that need repaired/replaced.

Might have to give my mechanic buddy a call, have him come over and walk me through some of this.

Also decided to make another modification, thanks to JeeperDon for the inspiration, but I like the look of the flush mount tail lights, just don't care for the LED lights so I flush mounted my factory tail lights.


Still have some clean up work to do on the tail lights, but that gives you the general idea. I have multiple pictures on the process, but I'm going to post them in the tech forum, that way if someone wants to do the same it's a little more complete write up. Well, that's it for now, check back in a few days, should get some more time this weekend to do some work.

edit: I did find a 8.8 for sale for $100, not sure if that's a good price or not? Thought I would ask, not sure what the gears are in it yet, the seller was going to see if he could read the plate on the housing to see the code on it. Fingers crossed, hoping to move into an upper 3 lower 4 gear range, think that would be good for being a daily driver, but still being able to keep up on the trails... thoughts?
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'95 YJ "Herky", 4.0 I6, D30 Front, D35 Rear, 3.07 gear, 33" BFG AT
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Unread 11-13-2014, 02:54 PM   #14
sdillinger
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Join Date: Aug 2009
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Nice project. You're starting right where I started; It was stock except lift and 33's.

3.07 gears with 33's was awful for 4 years. I went to 4.56 this past spring and can actually use 5th!

I'd say $100 is a good price for 8.8 as I paid $240. Just be careful, and axle swap leads to a domino effect. I'm swapping so I may as well do gears, doing gears so I may as well do lockers, need a conversion joint so I may as well do a SYE and driveshaft... Thats what happened to me!
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Unread 11-13-2014, 03:25 PM   #15
petertom13
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Location: Coon Rapids, Iowa
Posts: 137
Quote:
Originally Posted by sdillinger View Post
Nice project. You're starting right where I started; It was stock except lift and 33's.

3.07 gears with 33's was awful for 4 years. I went to 4.56 this past spring and can actually use 5th!

I'd say $100 is a good price for 8.8 as I paid $240. Just be careful, and axle swap leads to a domino effect. I'm swapping so I may as well do gears, doing gears so I may as well do lockers, need a conversion joint so I may as well do a SYE and driveshaft... Thats what happened to me!

Well, I'm kind of already thinking that I'm going to do the SYE, since I'm going to be tearing the tc apart. And while I'm into the tranny, might as well do the true neutral. I'll probably pick up the rear end, and just sit on it for awhile, if the gearing isn't correct/what I want, I could always resell it down the road.

Right now, I got it in my head that while I have the tub cleared out, I should just go ahead and clean/scuff it up, and do the rolled on Monstaliner. I know that I should have it professionally done, but $750 is a chunk, I would rather spend that kind of money on lockers/axles/gears. I can do the monstaliner for $145, hopefully I can sell something and get the money for it. Plus, for now I want to keep the carpet in it as well, so I really am not to concerned if it looks like a professional job or not, but I think since there is no rush, I can take my time and make it look pretty damn good. Just have to pick up a propane heater for the garage first, warden won't let me run the electric heater out there, killed our budget last year.
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'95 YJ "Herky", 4.0 I6, D30 Front, D35 Rear, 3.07 gear, 33" BFG AT
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