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91 YJ - purchased new, sold, just bought it back

29K views 138 replies 37 participants last post by  jeep63 
#1 ·
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. :2thumbsup::2thumbsup::highfive::highfive:

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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#98 ·
Found some cracks in the floor underneath the rear of the driver's seat bracket.

From above...


Up Close...


My plan is the drill holes at the end of each crack, and the "stitch" the cracks with a welder.

While I wait to "borrow" a welder, I finished cleaning up an old 4WD Hardware bumper/tire carrier I have. Here is the bumper portion after prime & paint...
 
#99 ·
Got the rollbars out. I had to drill three of the bolts and I stripped 4 torx bits; Sears ran out of them and is ordering more, so I can exchange the last 2.

I found this underneath the driver's side rollbar...


Need to cut and patch this now too.

I am glad I pulled the rollbars instead of just installing Monstaliner over the rollbars.

Hope to weld this up over the weekend. Really want to get this baby back on the road.
 
#109 ·
Sweet pics jeep63! Pretty cool your were able to get her back. I like the Jeep you have parked next her! How about post some pics of the 'Black Beauty'! I've got an 89 YJ in black myself.....no pics posted to date though.
 
#112 ·
#118 ·
I learned a lot during this project. One of the biggest learning lessons was the length of time required to complete the project. I started out planning on 2 months and 10 months later I was still putting the finishing touches on it.

I was a victim of my own 'scope creep' and kept expanding the project as I unbolted more components and saw the condition of each.

I enjoyed every part of the project though.

I wish you luck and may the Jeep Gods smile upon you!:cool:
 
#119 ·
I am finally getting around to cleaning up the engine compartment.

After seeing how "clean" Drednot's engine looked I was inspired to clean up mine.

This is the 'best' before shot I have


I removed a Rock-it air intake that I installed back when I thought the stock intake was not 'cool'.

The stock setup is so much better than the tube I had that was sucking air from right above the motor; not quite a CAI! :rolleyes:

I also decided to pull the valve cover to deal with the leaks that have developed. The oil baffles were caked with crud; especially the CCV valve from the air intake side.

Everything looks okay for 225k miles too.

I'm changing the Rubicon wheels to white too, so I'll post up pics once they are done.
 
#120 ·
Just read the entire thread. Great story and great job fixing up your Jeep.

I have a similar story. I bought a new 1989 YJ did thousands in mods and then sold it in 1997 to a guy who I had just met at that time. He drove it only one year got married had kids and completely lost interest in the Jeep. We became close friends from the sale of the Jeep. He let the Jeep sit from 1999 in his garage never even starting it. I fortunately was able to buy it back Febuaray 2014. Now I'm getting ready to start the project of getting it back on the road for this year.
 
#121 ·
Just read the entire thread. Great story and great job fixing up your Jeep.

I have a similar story. I bought a new 1989 YJ did thousands in mods and then sold it in 1997 to a guy who I had just met at that time. He drove it only one year got married had kids and completely lost interest in the Jeep. We became close friends from the sale of the Jeep. He let the Jeep sit from 1999 in his garage never even starting it. I fortunately was able to buy it back Febuaray 2014. Now I'm getting ready to start the project of getting it back on the road for this year.
Always fun to bring home that first Jeep! I look forward to following your build.
 
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