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2003 Black Wrangler X - Texas Jeep

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

  1. Jun 8, 2019 at 10:45 AM
    #41
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    148
    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.
    My apologizes for the lack of posting on my build/restore/refurbish of the 2003 TJ. The work I've been doing has had a few misc postings dealing with install issues, but mostly there hasn't been much to post about or to share any pics of the work that's been getting done. Here is a list of the things that have been accomplished since the last post:

    1) I pulled all the spark plugs and installed new Iridium tipped Auto Lites, along with a new coil rail

    2) I also pulled the fuel rail and injectors. Installed refurbished injectors and a new fuel rail since old one looked pretty bad (after 208,500 miles its no wonder)

    3) While I had the fuel rail off, I installed new manifold, fuel rail and injector insulation blankets from Design Engineering. That cleaned up the look amazingly well.

    4) I also installed new transmission hoses from the factory metal ones to the radiator. This is a temporary update until I pull the grill to paint it and then install the B&M transmission cooler at that point.

    5) I then removed the transmission skid plate to get better access to the transmission oil pan. i dropped the pan, removed the old gasket, resealed the pan and topped off the tranny fluids. I did have an issue with the nutserts, which I ended cutting out and putting news ones in.

    6) As you may see in other threads, I also inspected all the pinions seals for signs of leaks and the only one that was wet was the front differential seal. Getting it off was straight forward with a bit of effort, but getting the new one back on was a bit of a struggle. In the end, I used the seal that I got from my local Mopar dealer which did not have the cover/oil slinger, but it fit like a glove (if you had to use a wooden block and ball peen hammer to put gloves on) :)

    7) Starting tomorrow, I am dropping the transfer case skid plate (the larger one, as I already have the transmission skid off to service the transmission). I already have a bottle jack with wood block supporting the transmission and my floor jack supporting the skid itself. I've removed the four nuts holding the transfer case to the skid and have loosened one thread each of the six bolts that hold the skid, luckily no spinning nutserts so far. If so, I know how to cut them out and re-install new ones.

    Finally, Santa Claus has started delivering my new parts to start the upgrade part of this build thread. So far he has brought me - brands are a surprise until I get some pics and links:

    - a cat back exhaust system with black tipped tail pipe (its a black Jeep)
    - four two inch lift coils and four two inch longer shocks
    - a steering stabilizer and bracket to mount it

    St. Nick claims that he has given FedEx for delivery to my garage the additional parts:

    - eight adjustable control arms (uppers in black, lowers in red)
    - replacement transfer case cable
    - two track bars (front and rear) in red
    - rear sway bar and longer end links (front and rear)
    - new steering cross over kit with new drag link and tie rod (in red)
    - one inch aluminum spacer body lift kit that also replaces the stock rubber mounts
    - one motor mount lift set

    I also still need to get the rear main seal replaced, but I've decided to let a Jeep garage tackle that, if I had a lift I would try it, but without a lift it looks a bit tight for me to tackle it.
     
    Last edited: Jun 8, 2019
    UrbanCowboy likes this.
  2. Jun 10, 2019 at 3:06 PM
    #42
    The4x4Guys

    The4x4Guys [OP] Well-Known Member

    Joined:
    Apr 4, 2019
    Member:
    #3048
    Messages:
    148
    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.
    Today was an eventful day in the garage on the 2003 TJ project Jeep. Here is what was accomplished, with a few pics.

    1) Installed four new O2 sensors. I didn't have any codes, but in trying to update as many serviceable things as I can on a 16 year old Jeep, these were next on my list.

    2) Supported the transmission with a bottle jack and dropped the transfer case skid plate. The was amazing little rust, just bit of surface rust around the bolt holes and where the skid made contact with the frame. I used a wire brush on my drill and took all of the surface rust off both the skid and the frame and gave it a quick shot of flat black Rustoleum. Here are both skids with the touch ups done, but the factory paint looks great - I even power washed the old grease and dirt build up.

    IMG_0539.jpg

    3) Next I drained the transfer case at topped off with fresh ATF+4 fluid.

    4) Since the transfer case skid was off, I decided to tear out the old cat-back muffler and tailpipe. Thank you Dewalt sawzall for making it a 15 min project.

    IMG_0541.jpg

    5) I then broke open one of the many boxes of new parts to install.

    Here is old system and the new Banks Power Monster Exhaust System. I like the beefier sound, solid without being annoying.

    IMG_0543.jpg

    IMG_0544.jpg

    Don't worry, the old bumper is a gonner, but I am still deciding on what to replace it with.....
     
    aggrex likes this.

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