While I was in there it was the opportune time to replace my leaking manifold gasket:



Little Copper Spray this time just to be sure:


With all that done time for the new radiator to drop in:

Nice 1/2" of clearance between the fan & radiator

Wouldn't have gotten this much work done in a day by self:

Thanks ADAM!

Here she is all buttoned back up:

Somewhere in the middle of all this we stripped down the drivers side knuckle and replaced the ball joints:



Upper Ball Joint was shot because there was no Zerk or Cap covering it's grease hole. It was full of dirt. Also, replaced my drivers TRE because it wore it out.


In conclusion the jeep is back to running and driving like a dream



She'll idle for about 20min fine at 210, then she'll slowly creep up to 215 the Aux fan kicks in and pulls it back down. At high idle 1000rpm vs 750 the ZJ fan can keep up and keep it cool without the AUX fan. So for the trail I'll be adding a high idle switch & Aux fan override.

That is a lot accomplished!
The fan override switch is something I use often. Whenever I am driving the beach, it is usually on.
It's funny because if the wind is blowing, the jeeps temperature will fluctuate according to if I am going upwind or downwind (on beach, not on pavement).

The switch also allows for running of fan after engine shutdown, which I have found to be very useful. Just one or two minutes with that air passing over the manifolds and through transmission tunnel.
Using a yellow top battery, perfect for running components without engine on, within reason.

Started in on my wiring a little more last night.
Have everything label on my schematic and my junction box built for relays & fuses.

Need to make cuts in the dash for the new switches & mount the junction box.
Then the real fun can begin when I start wiring the options up.

Goal is to add:
1) High Idle Switch
2) AUX Fan Override
3) Move the Switch for my Air Horn
4) Roof Rack Light Switch
5) Trans Gear Selector Switch

Going to use all factory switches

Went out and tried to wire my extended idle switch today.
Pin 10 on the 60 pin PCM is purple and when grounded should yeild a high idle.

Mine did not, guess it only works when your pcm has that option programmed in.

Found this guy who had the same issue:
http://www.jeepforum.com/forum/f11/o...topics/2318801

Since the extended idle didn't work out I rebuilt a drive shaft for my SYE

Well started in on Hack and Tap today:



Marked the shaft:


Nice clean cut, used the under the jeep lathe:


Hole drilled, Yoke on:


Installed a Front Shaft:


Changed the Trans Case while I was at it.
Had some extra fluid so I topped of the Transmision, .5 quart low in 51k miles

Burped the radiator and replaced the gasket on tstat housing.

Lastly I rebuilt a broken lockout...


She ready for a Jeep meet tomorrow and a full weekend at Uwharrie

Well everything did good on the wheeling trip except for deciding I want a bigger trans cooler than the factory one.

So I picked up one over the weekend to toy with.


Last night I started in on my factory switches:

First up is my Second Gear Lock & Wiper Switches:


Second is my Roof Lights & Rear Defrost:


Last is where I cut out where the factory dash clock would be to install two more switches:













Have to remove some material from behind the dash to fit the switches flush:




The Left Switch is an AUX Fan Override the Right is my Air Horn.



Now that the switches are in I'll be working on the wiring the rest of the week.

Yaaaaaaay wiring!!!!!! lol

Could be worse... could be body work.

I actually do a lot of wiring at my job. I was getting annoyed looking at some of my past high school and early college work that I pieced together.

So that's what prompted the redo.

Well I didn't take pictures of everything and there is still more to do...

Here's the list of everything I'm covering in the overhaul:
Trans 1st Gear Lock Out
Roof Rack Lights
Air Horn
AUX Fan Override
Anti Theft
New Speaker Wires
Trailer Light Harness
Head Light Harness Upgrade

Everything has been tied back into the factory wiring harness for what I feel is clean.

Let's start with the First Gear Lock Out:
Here is the Trans Controller:


Taping into the solenoid power and stealing power from there as well:


Using the Factory Trans Switch from older XJ's:


Next Up is the Fan Override & Air Horn Switches:


You can see in this pic the clearance made behind the dash:


Everything tucked in behind the dash, before I had a lot of stuff run just behind the dash cover


Factory Fog Lamp Switch Purposed for Roof Lights


Dash Cover On:

Yeah I know what you mean. I used to suck at wiring and then I just kept practicing at it. I can do a pretty clean wiring job now, but I'm still not comfortable enough to do one on anything but my own vehicle now... well.. or trailers, but those are easy. I'm dreading doing the wiring on the green jeep I've been borrowing. Mainly because someone did some really questionable wiring on it prior to the current owner acquiring it. Put it to you this way, I put a fuse in the spot for the dome lights to work. Domes lights came on (yay, right?) and so did the radio... and then smoke started coming out of the headliner before melting - that's right, not popping, MELTING - the fuse. Almost burned the jeep down within the first week of having it. I've got quite a job ahead of me on that one.

Love that, I might have to trade out my clock when I get a selectable locker for my locker switch. That would look like my XJ came stock with a locker Ha! Ha!

Why trade out the clock? Should be room enough for the switches below it.