Here's what we have to work with

This vehicle is intact and viable for the street and four wheeling.Of course we believe it should be modified to perform better offroad and be more trustworthy on the road.

Vehicle: 1995 YJ Wrangler Jeep
Color: Red/black/gray
Price Paid: $2,200.00

What it came with when it was purchased:
Axles: Dana 35 Rear / Dana 30 Front
Transfer Case: 231
Tires: 33" BFG
Engine: 4-cylinder automatic 2.5L
Seats: Buckets in front, bench in rear- torn up a bit      
Soft Top, hard top
Suspension: Leaf Springs
Black Diamond 4" Suspension Lift
2" Body Lift
Power steering, brakes

THE PURCHASE PRICE INCLUDED THESE GOODIES TOO:
* Left rocker panel
* Hood * Left fender
* Spare tire rack
* Catalytic converter


          

What we are repairing

Fuel Pump and Sending Unit:
When testing the jeep we found it started hard and was losing fuel pressure when turned off. After looking into this problem further we discovered the fuel pressure was too high (should be 31 psi and it was 60 psi). This lead us to believe the fuel pump or fuel pressure regulator needed replacing. The regulator appears to be ok, so we moved on to removing the fuel tank. Once removed metal shavings were found inside and also on the fuel filter. The tank was flushed and cleaned and the hoses were replaced with new ones. Then we replaced the fuel pump and sending unit and mounted the gas tank back onto the Jeep. But in the process we broke off some of our exhaust (it was rotted and needed replacing anyway). While we hope this has solved the problem, we will keep a close eye on the regulator for now.

       

Wiring Mess :
The wiring under the dash resembled spaghetti so we cleaned it up, removed any unused wires and neatly taping up the rest.

General:
We are replacing all the fluids and filters (as needed).

      

 

Next on our list to modify

Body:
This jeep looks like it has been offroad before us, just look at the body. We are planning to repair the left side rocker, fender and hood. Using the extra parts that came with the purchase we should be able to fix this Jeep up and stay within our budget.

We are going to make some custom in-shop fabricated bumpers to replace the home-made ones on this Jeep now (we don't like these!!) Once all body work has been done (nothing fancy just make it bit straighter than it is now), we are going to paint it the company colors. Yellow body, black on the frame, grill, and windshield frame.

       

Exhaust:
This jeep is going to have the exhaust repaired and a catalytic converter installed by us.

Interior:
While rug may look nice in a vehicle, it gets wet and rots away fast in a four wheeler. That's why we are going to apply a bedliner product to the interior of our Jeep. It will be black and keep the inside looking good. Plus it's real easy to clean upafter a day romping through mud holes!

      

Winter Project

Engine Swap :
Oh yeah, we are going to swap out the 2.5L for a 4.0L! This will require more than just replacing the engine. The transmission, transfer case and drive shafts will all be replaced because they are all different. We will replace the wiring harness and computer using those from a donor vehicle. We are in the process of searching for this donor vehicle!

Axles :
This jeep will keep it's Dana 30 front axles but it's going to loose its Dana 35 rear. In its place we'll put a Dana 44 from a Scout for strength.

Wheels:
The bolt pattern on the front wheels is 5 on 4 1/2. The bolt pattern on the rear wheels will be 5 on 5 1/2 because of the Dana 44. We are going to use a spacer adapter combination to widen it 2" and kick down the bolt pattern so the front and rear wheels match.

     

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