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Unread 07-19-2014, 09:59 PM   #1
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
tjMtl's 2003 Sahara build

Welcome to my Jeep build diary. Much of this will be boring low level stuff, but hopefully you might see something interesting that you can use in your own builds.

This story starts in Feb 2014, I was looking for something inexpensive, which I could use as a third vehicle when I travel up north for work.

I found this TJ on Kijiji, and corresponded a bit before going to see it and eventually buying it. I had been reading the forums and was knowledgeable enough to recognize a Dana 44 when I saw one. lol

This Sahara was fully loaded when produced in 2003, came with the Dana 44 I mentioned as well as rear disc brakes, and dual tops.

The A/C is cold enough to get condensation on the center console, and the heater is outstanding as well.

It needed some work when I brought it home, and one of the first things I did was get some Studded Nokian Hakka Tires for it. I didn't particularly like the Alloys that it came with so they're me designated winter wheels now.




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Unread 07-19-2014, 10:04 PM   #2
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Cleaned Throttle Body a few weeks ago, seemed to even out the idle a little.







A pic of the connections, one slides on, and the other clips onto the ball.



A picture of the cables that were disconnected.

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Unread 07-19-2014, 10:10 PM   #3
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Installed Rancho RS9000XL shocks for my no lift TJ.

Did the fronts up North, and the rears here this summer. The bottoming out that I was having in the rear is gone, feels much safer now and my kids don't complain about riding in the back seat anymore.



Both upper bolts snapped on each side in the rear. I dremeled out the nut's by passing my cutting disc through the large hole where the end of the shock pokes through the upper mount location.









The other side.



POR15 and installed the shock.





Here you can see the new piping for the Walker Muffler that I had installed to get rid of the cheapo glasspack that was in there.

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Unread 07-19-2014, 10:13 PM   #4
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Saw the great reviews so got some Duratrac's in 31". My old tires were Dunlop winter tires that were out of round and probably led to my Pinion Seal leak that I have to take care of soon.

I got some refurbished Jeep Ravine Wheels and got rid of the Steelie's.

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Unread 07-19-2014, 10:15 PM   #5
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Installed some IPF 901 Driving Lights to help me with late night driving. Lots of animals where I drive.

No pic of the lights yet but here's the DRL module harness. I tapped into the High Beam indicator wire to trigger the lights off when I turn off my brights. I originally had them wired to the High Beam wire but it was screwy since the wire gets low pulsing voltage when the DRL's are on.

Pin 4 is the red with gray stripe.

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Unread 07-19-2014, 10:19 PM   #6
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Previous owner told me he changed all fluids, but I was having some shifting issues, like hard to take out of second, resistance getting into first, etc.

Decided to change the fluid to Redline MTL today.

Picked up a 17mm tool for the plugs, and this is what the drain plug magnet picked up.





What it looks like clean for comparison.



What the drained fluid looked like. Pretty brown.



So far I put about 15km's on it after the fluid change. Second is easy to get out of now. I'll see if that holds up.
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Unread 07-25-2014, 09:33 AM   #7
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
I've put about 500 km's on the Jeep after the tranny flush and it's MUCH better than it was before the switch. Jerry was right on with recommending the Redline MTL.
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Unread 09-25-2014, 09:02 AM   #8
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Windshield frame changed!

From this...






to this...



Which was powder coated to look like this...



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Unread 09-25-2014, 09:04 AM   #9
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Fighting the door bolts now, my rivet gun and screw buster is on the truck for delivery today!



This is what the inside of the door looks like.



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Unread 09-25-2014, 09:07 AM   #10
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Monstaliner and installed Tuffy center console with corner seat guards.













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Unread 09-25-2014, 09:08 AM   #11
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Got a Speedohealer module, works great

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Unread 09-25-2014, 09:09 AM   #12
tjMtl
Registered User
2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
My Ghetto Hardtop hoist made with scraps. Too tall but worked ok.



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Unread 09-29-2014, 09:22 AM   #13
tjMtl
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2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Rivet gun worked great, got 11 of 12 bolts out of the door side hinges. Drilled out last one and doors are installed. I put the Magnitude Engineering Door pins and bushings, the doors are tight and smooth now.





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Unread 09-29-2014, 09:24 AM   #14
tjMtl
Registered User
2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
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Unread 04-04-2015, 01:32 PM   #15
tjMtl
Registered User
2003 TJ Wrangler 
 
Join Date: Jan 2014
Location: Montreal, Quebec
Posts: 115
Installed my new starter, the one I had put on it was all rusted after only a few months. Hopefully this one will be ok.

I also picked up some Rigis SR-Q backup lights. I mounted them in my stock rear bumper. Burned out my dremel in the process.

IMG_3252 by TjMtl, on Flickr

IMG_3254 by TjMtl, on Flickr

Next week I will connect the reverse wire and mount the switch in the unused passenger airbag area on my dash.
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