Project Jeep is ALIVE! Jeep Wrangler YJ 4.0

Part 3: Old Jeeps Die HARD! Thermostatic Switch and Water Pump! 95 Wrangler 4.0


Customer States: Engine barely runs and has a severe lack of power. It also has the occasional no start or long cranking before it starts. So far I've found vacuum leaks, clogged ports, antifreeze leaks from the water pump and the electric fan is damaged. I had the fuel pump, filter, spark plugs, ignition wires, and a distributor cap and rotor. It also has a new coolant temp sensor, O2 sensor, MAP, intake temp, IAC and throttle position sensor replaced. The ECM / PCM has been replaced too. See part one.

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”Intro Music by Karl Casey @ White Bat Audio”
Thanks to Jesse for making the intro and graphic for us to enjoy!!!

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[Rekuzan]

PASSENGER SIDE SEAL: Yes, you DO have to remove the locker in order to service the seal, but it's actually super easy (barely an inconvenience) because once you get in there, you just use the same seal driver you did on the driver side.

[jonathanbloxam]

I think from the channel responses the subscribers and valued viewers are really loving the work you are doing in saving this iconic piece of history from the crusher. Wrangler is absolutely the right name given how much of a fight this lovely old girl sometimes gives you. Wife Unit/Whiskey Uniform channel is also a great new additional channel Ray highlighting the teamwork and background help you enjoy from WU. X Files editing for the litle ones is hilariously brilliant. You should be really proud on how you all have built this channel in such a short time.

[patrickchavez]

I am so gonna miss project jeep when she is done. I am not a mechanic but I do really enjoy watching everything you do, it must be very satisfying to take a vehicle apart, put new components in, put it all back together and be able to drive it with no noises an no problems! Awesome ray!!!

[unavailablenumbers]

Hey Ray, that's not a 4WD 'locker, ' that's the front axle disconnect. You'll want to go back in there. It's less agonizing than you think. Four bolts, gives you a big window, just pull the solenoid and the engagement arm as a single unit (easy with the axle out, ) pop the seal in same as you did in the diff, add some RTV or gasket tack to the crappy cork, and you're done. It has to be done outer halfshaft out though because you need the halfshaft ring out to do the seal. You DEFINITELY want to get in there because it's a major failure point on these. The cork gasket (JUNK) loves to leak, letting water in, and the oil seal is on the OUTSIDE of the disconnect. So those leaks get into the shiny new diff. Not good!
Denny's Driveshaft has you covered. Replace the pads (621059 "clip for shift fork", ) both E-clips (620979 and 621097, ) and the oil seal (you may have the wrong one - there's an 84-86 and an 87-94.) Costs about $10. For everything. Those E-clips are very important because they ARE single use. But again: add gasket tack or RTV to the cork gasket! Super light because it serves a spacing function, but also it loves to leak. This owner clearly loves to offroad and mud it, and that's the big weak point in the front axle for water intrusion. Be super careful with the diaphragm though - that's a $160+ kit if you need to replace it!
As folks have mentioned, there's a special tool for that seal. Pfft, screw that. Grab yourself something like a wobbly C-clamp, some flat metal, and you can do the math. ;)

[WOMANIZERJERRY]

I thought those plastic caps on the drag link were supposed to come off before installation, they were only on for protection during shipping that's why the threads didn't protrude the castle nut, and the cotter pin didn't fit.

[wolfc]

Living up north I nearly weep tears of joy when hub assemblies come out that easily. The last one was so bad I had to remove the suspension knuckle.

[Dis-Emboweled]

I always saw that bearing presser tool in my grandpa's tool box for freaking ever, and I never asked him what it was for. Thanks Ray

[NeoMorphUK]

Was weird when I thought “Why doesn’t Ray fold the wire coat hanger in two to make it stronger”… and Ray complied… instantly. Cue jaw dropping.

[jimlaredo]

That piece on the axle is called the “center axle disconnect” it is just a vacuum diaphragm that slides that ring over to lock the two half shafts together when you shift into 4 wheel drive. It’s very simple to remove/replace. There’s just a gasket behind that plate with the 4 bolts. The seal is in the axle tube there because that ring and fork need gear oil from the differential to stay lubricated.

[TheFirstGhirn]

I find myself reflexively brushing off dirt every time I watch you work on project jeep... ye ha.

[jc]

I was always told to tap the component while using a puller. Pressure and impact always worked better. That said, well done and good work.

[mmrob]

Bought a '95 wrangler just after I enlisted back in 98. Such a fun little thing for a 18 year old sailor. Miss that girl.

[ironrupik]

The diff seal on the passenger side is not at the pumpkin, it goes at the CAD. This allows the fluid to lubricate the CAD. Ah, but I see you are figuring it out. That seal really sucks to replace!

[kencramer]

Oh the old vacuum actuated locking half shafts on those old YJ's. There is a reason those went away. Hell lots of people got rid of the half shaft and just put a full length axle in there. But if memory serves, the axle seal is on the outside of that vacuum disconnect. And yes you have to open the disconnect to service it.

[SantaClaw]

I'd install a front propshaft too. Kinda makes that front LSD uhm... useless without it.

[SamayelIam]

cheese is Etch Cries ... This bit you did about gears painting ... saved me hundreds of dollars!

Getting that project on the road and out your garage because now you need that effin lift because you are busy ... you are going up a learning curve. Love the content.

Sent you $5 canadian dollars cuz I love you like a brothe3r, dont ever change !

[george]

I think that new exhaust sounds pretty nice.

[atlas]

they make real nice aftermarket seals for the ends of the axle tubes so they won't load up with dirt and you can even grease them!

[johndesaavedra]

I'm glad you addressed the final drive gear ratio versus oversize tires. Many of us wanted to know how the speedometer would be handled. The new gear ratio will be closer to matching the original speedometer to the tires.

[michaelridey]

You should make another T-shirt that says "Everything's A Hammer!" I'd go for one of those, since I've been known to use other objects for non-intended purposes in my shop. 3XLT, please.