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2003 Black Wrangler X - Texas Jeep

Discussion in 'Wrangler TJ Builds (1996-2006)' started by The4x4Guys, Apr 21, 2019.

  1. Apr 21, 2019 at 8:36 PM
    #1
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
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    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    Well today is officially the first day of the TJ's life with a Jeep Lover. I have big plans for this little ride. Tomorrow we start with a cleaning, vacuuming, and inspection. I plan on replacing the valve cover and gasket later this week, which hopefully is the source of the driveway drips. IMG_0390.jpg IMG_0396.jpg IMG_0398.jpg IMG_0402.jpg If that isn't it, then its likely the rear main seal.

    Here are my "Before Pics" more to come as the journey progresses.

    Bob
     
  2. Apr 22, 2019 at 12:27 PM
    #2
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    Day two included the following tasks:

    Examine the drip. Not a drip was left overnight, apparently it only drips after it has been running
    Remove the front and rear bumper end caps.
    Removed the front and read fender flares and short running board/flares
    Removed all interior carpeting
    Vacuumed out the interior, lots of sand and leaves, top must have been down while parked under a tree
    Removed the back seat for carpet removal and vacuuming, dusted it off and vacuumed too
    Removed the aftermarket trailer hitch
    Hosed off the first layer of dirt, exposing a millennia of bug guts. I'm going to need a paint safe solvent to removed thousands of bug guts.

    Here are some of today

    IMG_0406.jpg IMG_0412.jpg IMG_0408.jpg IMG_0417.jpg s before and after pics.

    IMG_0405.jpg
    IMG_0404.jpg

    Saving the carpet in case I need a template for the new rug. Not sure if I'm cleaning up the fender flares or biting the bullet and putting Bushwackers on.

    Waiting on engine refurb parts to arrive, so in the meantime, more cosmetic tasks tomorrow. Wipe out interior, check all fluids, and inspect the brakes front and rear.
     
    Last edited: Apr 23, 2019
    JKBob 25 and aggrex like this.
  3. Apr 23, 2019 at 11:40 AM
    #3
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    Day 3

    Mores cosmetic tasks, while waiting for my boatload of part to be delivered. Today I:

    1) Used Formula 409 to wipe out cargo floor, passenger and drivers foot wells, interior body sides
    2) Washed windshield three time to get all the grime and bugs off. Still a few streaks, but 99% better than it was
    3) Took off all four wheels to inspect rotors, pads, drums and shoes. All I can say is, I won't be driving it on the street until they are all replaced!
    4) While Jeep had its tires off I inspected a few bushings, and all I can say is "what bushings?"
    5) Used the tire take off to replace all the lug nuts. The ones on there were nasty, partially rounded, a mixed set of locking lugs has been removed and an inexpensive set of chrome lugs ahs been put on until I replace all the tires and wheels. Tires look dry and cracked.


    I'm headed to Walmart later today for a shopping list of fluids - diff, engine, tranny, power steering, brakes, anti-freeze, washer fluid. Next up, order the replacement brakes.

    Ps. I'm seriously considering bedliner for the floors, but the prep, removal of the seats and console sounds a bit much, as well as removing all drain plugs and back seat/cargo brackets. Someone tell me it is worth the trouble by showing amazing pictures of theirs!!

    IMG_0420.jpg
    IMG_0422.jpg
     
    JKBob 25 likes this.
  4. Apr 23, 2019 at 11:44 AM
    #4
    Prerunner1982

    Prerunner1982 Well-Known Member

    Joined:
    Aug 4, 2017
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    Jon
    Vehicle:
    93 XJ 2 door, 97 XJ 4 door, 00 XJ 4 door
    You missed a spot. ;)

    That looks much better.
     
    JKBob 25 and TJ_abuser like this.
  5. Apr 23, 2019 at 12:00 PM
    #5
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    That's funny. My wife came out to look at it and turned her nose up and said "is that the best you can do?"

    LOL
     
    JKBob 25 and TJ_abuser like this.
  6. May 1, 2019 at 6:26 PM
    #6
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    Modest progress today. The darn bolt is still broken but I'm waiting on new drill bits to attempt to drill it out. I couldn't wait to get on with my build so today I put the TJ up on four jack stands and started by replacing both front rotors and brake pads. It took a bit longer than I expected and I had to leave unfinished as I decided to also replace the bolts that hold the calipers to the spindle. So once they arrive, I will button up the front and start on the back drums and shoes (also being replaced).

    Given that I already have removed the fender flares, I can see that I have good access to the front shocks and coils. Now my thinking cap is working in overdrive on what to do about all that. The bump stops are in bad shape and need replaced too.
     
    Last edited: May 1, 2019
    JKBob 25 likes this.
  7. May 1, 2019 at 7:18 PM
    #7
    JKBob 25

    JKBob 25 Well-Known Member

    Joined:
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    First Name:
    Bob
    Jersey Shore, NJ
    Vehicle:
    2016 JK Wrangler Sport
    2" Superlift kit. 315/ 70/17.
    Awesome progress dude. You got attention. :thumbsup::popcorn:
     
  8. May 5, 2019 at 10:57 AM
    #8
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    As Gerald Ford said after pardoning Richard Nixon "At last our long national nightmare is over" my paraphrased version is "At last my long nightmare with the un-removable broken bolt (with extractor embedded) is over".

    It was a multi-part process that involved using a cutting wheel to cut off most of the captive nut from underneath (only had room for a Dremel with a 1 1/2 inch cutting disk, but it did the job). The remaining 3/16 of threads still refused to come out, so I drilled a pilot hole with a 1/16 bit through the edge of the threads, then enlarged it with a 1/8 in bit. Then took out a punch and 2 1/2 pound Thor hammer and after two or three solid hits, the bolt shards exited the hole. I then used a 5/16 drill bit to open up the hole beyond the size of the original threads.

    My plan is to get a similar but longer bolt and put a nut and washer on it from underneath. Should work just fine.


    In the meantime, the build continued over the past several days with the removal of the front rotors and pads and removal of rear drums and shoes. All nice new shiny parts are installed. Now on to de-greasing the engine and engine bay prior to installing the new valve cover and gasket.

    Thanks for everyone's support and constructive comments throughout the "bolt ordeal".

    The snapped off top of bolt and the Dremeled off bottom portion, as compared to a full bolt.
    IMG_0455.jpg

    The underside of the Jeep after cutting off the bolt stub and the captive nut bracket.

    IMG_0454.jpg

    The final look at the top side after drilling out the hole.

    578769708.jpg
     
    Last edited: May 5, 2019
    JKBob 25 and aggrex like this.
  9. May 5, 2019 at 11:11 AM
    #9
    morzh

    morzh Active Member

    Joined:
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    First Name:
    Mike
    Jackson NJ
    Vehicle:
    Jeep Grand Cherokee
    Whew!
    Congrats! This 0.1% of the total job is over. But this is a nasty 0.1% and counts as 2.5%. :)
    (Sex is 1% of marriage but it can ruin the other 99%) :)
     
    JKBob 25 and The4x4Guys [OP] like this.
  10. May 5, 2019 at 11:13 AM
    #10
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
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    Member:
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    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    Yep, marriage is work - almost at 30 years and better than Love, we have Deep Toleration of each other...LOL
     
    JKBob 25 likes this.
  11. May 5, 2019 at 11:15 AM
    #11
    morzh

    morzh Active Member

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    Agreed (16 years with us and I like the Deep Toleration definition).
     
    JKBob 25 likes this.
  12. May 5, 2019 at 11:19 AM
    #12
    TJ_abuser

    TJ_abuser Well-Known Member

    Joined:
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    Member:
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    First Name:
    Todd
    Vehicle:
    2005 jeep unlimited
    2 inch lift, bumper and winch 33" mud claw
    The4x4Guys [OP] likes this.
  13. May 5, 2019 at 11:20 AM
    #13
    TJ_abuser

    TJ_abuser Well-Known Member

    Joined:
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    Todd
    Vehicle:
    2005 jeep unlimited
    2 inch lift, bumper and winch 33" mud claw
    30 years for us this month
     
  14. May 5, 2019 at 11:28 AM
    #14
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    I have to give some credit to my friend Bill. He's retired now but used to have a shop restoring classic cars. He stopped by this week from his home in Florida and came prepared to work. After he reviewed the situation and my complement of tools, he said "You're gonna have to cut that sucker off or you will drill for the next two weeks into that extractor". Fifteen minutes and two Dremel cutting wheels later that bottom portion was off. Then he looked at my ball-peen hammer and said "You need a real hammer" off to Harbor Freight we went, then drinks and dinner kept us from finalizing the deed. After my coffee this morning, i decided to finish the job. I am so glad that monkey is off my back.

    As Bill said "If that's the last broken bolt you have on a 16 year old Jeep, you've won the lottery my friend". He was impressed with its lack of rust and overall condition. He even offered to buy it from me when its done.....if I like it when its done, its gonna be a keeper until I find a Rubicon in similar shape.
     
    JKBob 25 and TJ_abuser like this.
  15. May 6, 2019 at 7:22 PM
    #15
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    Day 16 of the Build

    Roll bar covers removed, sound bar and wiring disconnected, passenger seat removed.

    New seat belts and roll bar covers to be delivered this week.

    Visited with local LineX, $800 for interior, $4500 for exterior (as long as its black) that is too rich for me, home spray of the interior is going to have to work.

    If I didn't mention it earlier in the thread, front rotors and pads replaced over the weekend, read drums and shoes replaced too.

    The plan is to replace the valve cover and gasket in the next day or so, then de-grease the engine and engine bay before replacing other engine components.

    PS. Does anyone know the trick to removed the plate for the shifter (Park, Neutral, Reverse, Drive, Low) from the shift lever itself (as you can see in the pic below)?

    IMG_0460.jpg IMG_0461.jpg IMG_0464.jpg
     
    JKBob 25 likes this.
  16. May 7, 2019 at 7:26 PM
    #16
    JKBob 25

    JKBob 25 Well-Known Member

    Joined:
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    First Name:
    Bob
    Jersey Shore, NJ
    Vehicle:
    2016 JK Wrangler Sport
    2" Superlift kit. 315/ 70/17.
    I'm subbed. Almost fell asleep with the broken bolt story.....:coffee:. But I'm still here.
    Looking awesome so far @The4x4Guys .
     
    The4x4Guys [OP] and aggrex like this.
  17. May 7, 2019 at 7:49 PM
    #17
    TJ_abuser

    TJ_abuser Well-Known Member

    Joined:
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    Member:
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    Messages:
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    First Name:
    Todd
    Vehicle:
    2005 jeep unlimited
    2 inch lift, bumper and winch 33" mud claw
    Lol Bob me too thought we were never get that bolt out
     
    The4x4Guys [OP] likes this.
  18. May 7, 2019 at 7:49 PM
    #18
    TJ_abuser

    TJ_abuser Well-Known Member

    Joined:
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    826
    First Name:
    Todd
    Vehicle:
    2005 jeep unlimited
    2 inch lift, bumper and winch 33" mud claw
    Jeep is the only vehicle that still looks sexy disassembled.
     
    The4x4Guys [OP] likes this.
  19. May 7, 2019 at 7:50 PM
    #19
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    121
    Gender:
    Male
    First Name:
    Bob
    Parker, TX
    Vehicle:
    2018 Black JLUR
    Mopar 2" lift, 37" BFG KO2's, KMC Rockstar 17" wheels, JCR Offroad front and rear bumpers, WARN Zeon 10-S, CoolTech CB Radio Kit, Rock Slide Engineering step sliders, TeraFlex adjustable steering stabilizer, Rock Krawler adjustable track bars,Magnaflow dual tip black exhaust.
    Sorry guys. I really wanted to get it out and keep the threads. But after so much time devoted to drilling and twisting, I just said WTF and cut the damn thing out.

    On to better things now!
     
  20. May 7, 2019 at 7:52 PM
    #20
    TJ_abuser

    TJ_abuser Well-Known Member

    Joined:
    Sep 18, 2018
    Member:
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    Messages:
    826
    First Name:
    Todd
    Vehicle:
    2005 jeep unlimited
    2 inch lift, bumper and winch 33" mud claw
    Way more patience than me Bob I would have gotten the flaming hatchet out 4 posts back lol
     
    aggrex likes this.

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