That is not a bad idea at all. But I am lazy and dont have to worry about rust out here haha. I might give it another pressure wash to get the rest of the brown coolant stains off but that as far as I am going unless it does start to rust one day. All the paint is still good down there as far as I can tell. Just needs a good cleaning.

 

The deed has been done. It is back together and on the ground. Still need to put the new rear shocks in. But the initial test drive went perfect. No clunks at all and it feels a lot tighter.

 

Good work man! Ive had to adjust my stearing a bit to get rid of some clunks while turning. whats next?

 

Thanks! Glad to be done with that part of the restoration. Still got a pretty big list to do and all before the end of August.

- find out why the valve cover wont stop leaking
- install rear shocks
- heater core
- radiator
- possibly a new steering box
- new muffler
- headliner
- wiper blades

And after all that, a fresh paint job.

 

Alright, I think I am far enough along to post an update. As some of you have already seen, its been heater core time over the past couple days. Got everything out last night. Today I should be able to get the new heater core in and everything cleaned and prepped for re-installation. Then more fun putting it all back together. Its been about 10 years since I have done a heater core on an XJ so its like doing it for the first time again!

Here is the basic breakdown of one layer at a time.

 

I am completely rebuilding my HVAC unit (cleaning all parts, ducts, and vents, blend door foam, case insulation, evap. core, heater core, and all seals).
I was looking on line at the MOPAR seal kits, and oh my gosh! Some of the seals are like crazy expensive and not that great.
So I was trying to figure out what to use on a few of the seals (cowl seal, blower motor, and heater & freon line seal). Those seals are what are responsible for ruining the floors just as much as a leaking heater core.

A few days later I was working out in my garden kneeling on a foam pad, and it came to me that the pad is made out of a really tough rubberized foam.
So we went to Home Depot, and the garden pads they had were to thin, then went to Lowes and found the PERFECT pad.
I bought two of these to make my seals out of. They were like $9.00 each I think?

 

Very interesting.... I looked at the factory Mopar seals too and said heck no. Way over priced. I have a bunch of leftover foam from my Bug that I am going to use for some of the ducts but for the bigger pieces I wasnt sure what to do. I think you nailed it with that mat. Now I have to see where the closest Lowes is. Thanks!

BTW - Is there a Lowes up your way or did you have to come down the hill? I am thinking the one in Fontana might be the closest. But I hope not cause that is 30 min away with no traffic...

 

We came down the hill to the Lowes over on Sierra Lakes by COSTCO.
We had to go to COSTCO & then to Rialto to pick up materials from J&J Upholstery supplies. Amazingly cool mom and pop store.

 

Well that sucks. I was hoping there was one closer. I guess if I'm going out that way I will have to check out the upholstery shop too. Need to do a headliner too. Did they have a pretty good selection?

 

Thank you for showing us how this comes apart man. Mine is going to get junked if the heater core ever starts leaking. lol

Now I see why you were hesitant to do this.

 

Haha no problem. And yes this is exactly why I was putting it off for so long. But again, its really not bad to do. Just very time consuming. I think you have a bigger project with your roof then a heater core.

 

I know you are right about that fact. lol But man... they sure buried that box well!

 

Yes they did a great job of making sure everything has to come out to get to it. But hopefully I won't have to ever do it again. Well at least on this Jeep.

 

How much you want to bet you sell it or junk it before you do it again? lol

 

Nah, I would do it again if I had to. I would prefer to work on the inside of a car rather then something covered in oil.

Now for the rather large picture dump. I had a good amount of time to work on it this weekend so I got quite a bit done.



After popping the lid, this is what I found.



Not sure if this foam stuff was supposed to be there or got stuck in it.



Should have just hosed it off and reused it!



All parts nice and clean.



New core going back in. I didnt like the gaps it had around the whole thing so I used some foam to seal everything off. Much better



This flap did not have any kind of foam on it so I sealed it off with a layer of foam as well.



Just about ready to throw the lid back on.



Re-foamed this guy too.



Also put a new foam seal on the intake side of the box



This little piece of foam has seen some better days.



I cloned the old one on to a new piece of foam.



Much better.



Back in!



Next up was this half of the dash



Got it all cleaned and ready to go back in



And its back in!



Good tight seal



This is the only piece of foam I didnt replace. I knew it wasnt sealing before but had a plan.



Added more foam and it seals now.



Nice clean ducts with more new foam



Starting to look like a dash again



And done for the night.

Tonight I should finally be able to get it all back together. I did plug the battery back in to verify that everything works and it does. Thats good news to me!