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Project: Alexia's "Nice Jeep"

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140K views 446 replies 115 participants last post by  NashvilleTJ  
#1 · (Edited)
Project: Alexia's "Nice Jeep"
On 10/25/2008 I drove a combined twenty hours from Pennsylvania to Virginia to buy this Jeep. I have always wanted the newer Wrangler in Electric Lime Green, but I was just get out of high school when they came out. I also wanted an Unlimited at the time as well! I patiently wait checking for sale listings and eventually I find it! A 2004 Jeep Wrangler Unlimited in Electric Lime Green. I found both of what I wanted in the same Jeep for cheap! I paid $10,000 total for the Jeep, $4,000 less than suggested retail. It has a few issues, but the savings on the Jeep actually is much better for fixing those issues.

I will be writing more posts through out the day as I prepare the photographs and upload them to my server. I already have a few things done and will be working on locks tonight.

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Chapters:
1.) Inspection
2.) Electrical Repairs
3.) Security Repairs
4.) Sound System
5.) Front Bumper
6.) Build Day One(Parts Arriving)
7.) Build Day Two(Broken shock bolts)
8.) Build Day Three(Lift is Done!)
9.) Build Day Four(Sway Bar, Stabilizer, Power Door Locks)
10.) Tires
11.) Build Day Five(Tummy Tucker)
12.) U-POL Raptor - Color Matched
13.) Savvy Off Road LED Tail Lights
14.) MOPAR Speed Control Kit
15.) Fender Flares
16.) ARB Air Compressor

Materials and Items List:
Priority
Tires - 31X10.5R15 BFGoodrich All-Terrain T/A KO - $700
Lock Cylinder - Dealership - $50 - INSTALLED
Stereo Adapter - Chrysler/Jeep In-dash Receiver Kit Fits select 1998-up - $15 - INSTALLED
Stereo - Pioneer DEH-P6000UB Pioneer DEH-P6000UB CD - Owned - INSTALLED
Locking Gas Cap - $15 - INSTALLED

Extra
Power Windows - Jeep "TJ" Power Window Kit - $240
Power Door Locks - Universal Power Door Lock Kit (4 Door) - $45 - INSTALLED
Keyless Entry and Alarm - Commando KE-30-I Keyless Entry - $45 - INSTALLED
Front Bumper - Bestop 42901-01 - HighRock 4x4™ Front Bumper - $600 - INSTALLED, Paid $250
Savvy Off Road LED Tail Lights - Savvy Off Road LED Tail Lights - $215 - INSTALLED
 
#4 ·
Inspection

One of the first things I needed to do was inspect the entire Jeep for issues and prioritize what I needed to repair in my project.

1.) Tires - There are four different brands and five different models of tires on this Jeep. Futura, BFGoodrich, Goodyear, and Generic Wal-Mart Radial.
2.) Passenger door lock has been attacked with a screw driver and needs replaced.
3.) Minor paint scratches around door locks and foot steps.
4.) Front left fender needs some minor straightening.
5.) Chrome grill guard is half broken and needs to be removed.
6.) Rear hatch inside door needs some touch up paint.
7.) Broken alarm needs removed.
8.) Blower motor resistor needs replaced.
 
J
#17 ·
Alexia said:
Inspection

One of the first things I needed to do was inspect the entire Jeep for issues and prioritize what I needed to repair in my project.

1.) Tires - There are four different brands and five different models of tires on this Jeep. Futura, BFGoodrich, Goodyear, and Generic Wal-Mart Radial.
2.) Passenger door lock has been attacked with a screw driver and needs replaced.
3.) Minor paint scratches around door locks and foot steps.
4.) Front left fender needs some minor straightening.
5.) Chrome grill guard is half broken and needs to be removed.
6.) Rear hatch inside door needs some touch up paint.
7.) Broken alarm needs removed.
8.) Blower motor resistor needs replaced.
Click to expand...
I am curious to see the replacement of the pass side door lock, my TJ has the same issue, and sometimes it'd be nice to be able to lock or unlock that side from the outside. :thumbsup: Nice find.
 
#9 · (Edited)
The NP242 is the Selec-Trac so I can have 4WD Full Time. We get plenty of light snow around here that the NP242 is great for handling. As well, if I get the AW4 with the NP242 already on it there will be less modification to bolt it on to the motor.
 
#10 ·
I am not planning to install a body lift and I am probably only going to put in a two inch budget lift. I could put 33" tires on there, but I am afraid they would rub too much when flexing.
 
#13 ·
I dig that color. My wife mentioned wanting an Electric Lime Green LJ. Now she's thinking JK.
 
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#18 ·
Good score there, neighbor...looks good. As for the grill guard, I have the same one on mine (came w/ the jeep and keeps the deer off the body when they jump in front of you)...if you do decide to keep it, wax it a lot, as that will rust quickly...ask how I know. You can fit 33's with a 2" bb, I've got 33x9.50 BFG A/T on mine with zero rubbing at flex and full steering lock
 
#20 ·
Electrical Repair

A few of the reasons the dealer took so much money off was due to electrical issues. The first was that the blower motor only had one speed. I replaced the resistor for $20 and did not tell them. The second reason was that the hard top's wiper, sprayer, and defroster did not work. I did not bother to tell them it was not plugged in!

The third reason is this Jeep had an after market alarm installed and unfortunately the dealer was not given the remotes to control. It was annoying, broken, and needed to go.

Below is the large mess of wires I removed. The installer hacked directly into the wires going into the ignition and it was a mess. I had to splice wires back together and apply new insulation to the wires where needed.

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#21 ·
Security Repairs

It looks like some one tried to break into this Jeep at some point. The passenger side door lock was destroyed by a screw driver and the paint around it is marred with deep scratches.
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To start the process of replacing the door lock cylinder you will need some basic tools. Pliers, flat head screw drivers, a hammer, and possibly a rotary cutter. It is best to by a full replacement lock cylinder from a dealership for $50 since the smallest notch in the wrong place can prevent the cylinder from turning.
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Here is the uninstalled cylinder up close.
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Start by removing the C clip and actuator arm on the back of the cylinder.
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Remove the metal cover the holds the cylinder in place. You will have to destroy it when removing it since it is crimped on. The replacement kit comes with both chrome and black covers.
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The cylinder should now come free. Tap with a hammer from the back gently if it does not slide out.
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Kbrawlz on YouTube provides an excellent guide on how to transfer the pins and springs to the new cylinder.
[yt]-uv3GOfrWG4&hl=en&fs=1&rel=0[/yt]

Transfer all of the pins and springs over to the new cylinder in the same order and reassemble. Be sure to grease the cylinder with the include white lithium grease and test your key to make sure it turns easily. I had to grind the lock pins just a tiny bit to make it all move smoothly.
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Install the new flappy door.
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Carefully crimp on the new cover and you are done! Reinstall the door lock into your door.
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#56 ·
Alexia said:
Security Repairs

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Click to expand...
Did you save the black metal covers? If so, I like to buy from you.

I've been looking for a pair to re-key half-doors I bought.

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#26 ·
The 2004 package had both face plates in it. It was part number 4864-651. For a 1997 it is listed as 4778-123 and I am not sure if it includes both face plates. The 2004 and 1997 parts list does not specify which colors you get and mine just came with both. The pins and springs will have to be transferred from the existing lock and moved to the new cylinder. You can also buy all the parts individually for the lock cylinder assembly if you only need certain pieces.
 
J
#29 ·
Thanks for the info. I am curious of the condition of the lock before you replaced it--were you able to stick the key in the door and turn it, but nothing would happen? That's basically what mine does, and you can see the opening is all jacked up from the outside. I'm guessing you were able to swap the pins and such with no problems--none of them were damaged?
 
#30 ·
I could not get the key to even reach the first pin. The flappy door inside the lock was blocking the key from entering.

I only had an issue with the first pin that was slightly bent from screw driver hammering. I used a Dremel to cut off the old cylinder around it and lightly hammered it back straight to reuse it.

Make sure to clean the old gunk off the pins and lubricate with the new white lithium grease. I greased it by completely assembly the unit, squirting the grease in from the slot along the top, and turning the cylinder around. If you squirt the grease directly into the key hole in the cylinder or on the pins you risk have a greasy key every time you use it.
 
#34 ·
A slight set back on getting to the next step of the project! The door lock outer cylinder is too big to fit in the door even though it is a direct replacement. I will have to get a file and take the edges of the hole in to make it fit.
 
#35 ·
I fixed the issue! The stock cylinder goes in with the half side of the cylinder down. The replacement goes in upside down.

On to what I have selected for my possible lift, rims, and tires. I am going for a black on green theme.

Rims - I am looking for an all black rims and I have one so far that I really like.
First Choice: http://www.tirerack.com/images/wheels/atx/swap/atx_chamber_bt_1000.jpg - Not sure about the teflon coating deal since teflon tends to scratch way too easily.
Second Choice: http://www.dpgoffroad.com/images/eaglealloys/185.jpg

Tires - BFGoodrich All-Terrain T/A KO 33X10.5R15

Lift - Rubicon Express 2" Budget Lift with mono tubes. I am trying to piece together an Old Man Emu setup, but I am not finding any already made kits. Though I might ask Dirk at DPG if he can put together a custom kit. He set me up with my XJ kit years ago and his offering of TJ/LJ kits are tempting for the prices.
 
#39 ·
I would paint the shocks black to hide them. :D I actually found the Rough Country deal with full springs listed. Once they get back to me if it works for LJs I will probably go for that instead.
 
#38 ·
I'm looking at black wheels as well. Check out the Predator from AR. They come in black teflon as well. I was also looking at a Pro Comp wheel, I think it was series 1089 off the top of my head. Either way, good look.
 
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#40 · (Edited)
This is a minor update of a few things done. I repaired the hard top wiper and defroster features. I had to rebuild the wiper motor to get it moving again and reattached the defroster tab that was broken off. I also installed the stereo over the week end. The Jeep is turning out nicer every time I touch it. :D I will have to take a few more photographs soon.
 
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