New to me 96 to play with

Hello friends,

Was looking for a new project of my normal OBS Ford flavors, but an animal caretaker at the barn I manage was in over her head with this '96.

Not safe at all with a sheared off steering box mount that would turn the wheel a full spin before any thing would happen. Among many other things. Shop quoted her $5K to fix it all. Gave her 5 instead and now have a tinkering project.

Smart thing would have been to come back with diesel truck and trailer, but ehhh, we'll just send it. In the dark. Actually. The LED lights failed halfway home, and only one bumper light worked. Next day we'll fix that up...

Got carried away with the amazons, but these hardcore tech projects need to start somewhere.

And right off the get go, I lock the keys in it.

Well that was easy. Too easy.

Then the next day I come across a big block 5 speed OBS for $1000. Couldn't say no to two projects.

Used the universal key to take off the shin smacker 2000. Can these things even tow? I'm capping out at 65 sounding like the space shuttle at launch.

Well, put that back in because the hatch won't stay open. Another trip back to autozone time.

Better.

A previous owner decided it was a good idea to put a flowmaster 40 on as an exhaust. Hard pass, although I do need that muffler for the big block OBS project, so it didn't go far. Simple stock exhaust now lets you hear the radio inside.

Absolutely love the yard down the way from me. Saw on their website this sweetie with a good front bumper.

For the crying southern guys that only have surface rust.

I'm from PA. Rust doesn't scare me.

Better, but I do want a winch.

Now, the exhaust is better, but still sounds like the space shuttle inside. Rock Auto'd these seals.

Wasn't a fan of the rusted out aftermarket rims to put new tires on, so got excited when this came to the junkyard.

Unfortunately, only three of the four were factory wagon wheels. The fourth is a Ford explorer spare rim. Did get a fifth aftermarket wagon wheel and a nice 30" spare though.

Instead of no prep drag racing, we're gonna do no prep spray painting.

If someone wants to sell a fourth OEM Jeep wagon wheel, I'll pay for it and shipping.

Went with 31x10.5 Firestone Destination XTs. Have a set on a Bronco I'm very happy with. Unfortunately I found they are getting harder to fine. Had to go to 3 different Firestones to get 4. Fortunately I have a tire machine at work.

Good enough for me.

The previous owner stopped me at work and said she still had some parts left over she forgot to tell me about. One of them was a non smashed hatch. I didn't know they were made of all fiberglass, so it was a pretty easy swap.

Adding some light to the situation.

Great idea I had was to talk the boss into buying a lift for the shop. After assembly, you gotta test it somehow.

Bought the roof rack off amazon, but I wasn't happy with it sliding around no matter how tight the clamps were. Junkyard grabbed two more roof bows and drilled holes.

That ain't goin' nowhere!

Adrianspeeder

Junkyard win! A winch bumper was still on by the time I made it there because she was welded in place. Six batteries later, I have a new prize.

I couldn't just remount the same way, because I have auto transmission cooler lines in the way, so welded up a spacer bracket and bolted the whole deal together with some bracing plates.

Hit up the ole TSC and I think a 9K will be fine for daily driver mall crawler status.

Only downside is I don't really have a spot for the KCs. The welder on call for the equestrian center I work at said he could make a pretty mount pretty quick for a six pack.

Snow plow status!

Sorry things got a little out of order.

Dude liked red extra lights and flames.

Yeah, that's gotta go. The dog won't like all the red.

Triggering wiring alert.

There was a center console switch panel already in the Jeep. Figured it be used for lights and such. On the test drive she said, "Turn on the key, but it doesn't do anything. Then you need the secret code to flip these six switches into a combination, then hit the hidden button for the starter." What? You'd need at least three relays to make toggle switches do that...

Anyway, pulled the cover off the column and this is the difference between an electrician/technician and some hack that can make electricity work.

Sometimes she said it still wouldn't start, but wait twenty minutes and it always will. Started with deleting the 19dickity2 alarm system, and other unconnected radio wires.

What was left is everything tied to relays, rocker switches, and the factory harness under the column with friggin wire nuts. More angering, was the dude flush cut the wires into the factory ignition switch connector. Time for a parts store and junkyard run.

These ain't even expensive.

Unfortunately struck out at the junkyard that day, and didn't have a harness that would work. However, I've had to do my own hack repairs before on other things. Just need a diagram.

Ooo that's cringe.

All that to do nothing good that a stock ignition switch can do.

The junkyard provides! I feel better now.

Last thing to fix before driving around was the steering issue. For sure the steering box pulled through the body weld and needed the full repair of outside brace and kickstand to the passenger side brace. If I was going that far, might as well change the steering box too. Puller didn't even need a lot of force, so I'll call it a win.

After driving it a few times to work, I was feeling more confidant. Trouble is the drive to work was topping out at 45mph. Friend needed a ride from the airport and my diesel was still hooked to a horse trailer. Let's take the Jeep. Bad idea. Above 65, which is still 30 under what the idiots on the highway are blowing by me doing, she got into a rocking like a boat on the ocean. No shit, my friend got car sick coming back, and she's a pilot I've flown with many times. Let's put this back on the lift and connect the swaybar that is wired up out of the way. I figured the swaybar being disconnected wasn't the cause, but it couldn't hurt.

Good thing he just wire tied it out of the way instead of removal. I only had to buy the new end links.

Then I saw the problem. Both sides had cracked stock leaf springs over the four inch blocks. Dammit. Spend money and ordered new four inch lift springs.

Harbor freight jackstands on blocks of wood and tire? Check. Cheater pipe? Check. Bolts not turning in shackle? Check.

Cheated with the angle grinder and the stock spring came out in pieces.

More better.

That was so much fun. We get to do it again! Started off way easier without a grinder on this side.

Not sure how, but this side just unbolted no fuss.

Round it out with new shocks.

Well, I thought the four inch springs would match up with the stock springs and four inch blocks that came out. Not even close. It's like a reverse Carolina squat. I don't like it.

Saw this other cool unit at Harbor Freight. I don't like the look of mine. Really gotta level this out. Thinking about taking out the bottom leaf on each side and seeing what that does.

It was a great day for junkyard hunting. 6 XJs had been put in the line on the same day. Pack a lunch and let's go play.

This one had a score of an owners manual. I had been unsuccessful in finding a 1996 fuse panel diagram online, so I got hyped up.

Hell yeah, I love steel. You're coming home too.

Grinder and paint makes you the welder you ain't was not a motto of this homemade unit. Easy fix though. Badges? We don't need no stinkin' badges!

Next XJ down the line had a guy trying to pull the transmission, but not enough tools. Struck a deal to teamwork out the transmission if I could score having a spare transfer case.

Snagged some missing screws and a tail light from this 4x2 rig. I didn't know they made them.

Added some weld, and installed no fuss.

Got around to putting new mount points for the front sway bar links. They were warn halfway through and I couldn't turn them out when I has previously put in the new front links. Oh. They don't turn out. Get the press!

One of the nutplates had broken so made two shims of scrap steel with bolts and nuts. Good to go. This thing steers straight and rides smooth.

Adrianspeeder

Wanted to see how terrible the axle fluid front and rear would be. Not sure these axle types, but rockauto got the new gaskets correct first try.

While both have no lockers or limited slip, there ain't no glitter, so I'll call it a win.

For those outside of Colorado Springs. The mighty Pikes Peak is a fun drive that tests how well your shitbox truck is put together. 14K feet of up and down fun. Ignore the minivan in the reflection that was pissed I was taking so long going up.

That was the last thing I did in that less than ideal for me job at the Air Force Academy. Pack it all up, and roll down to my next assignment in New Mexico.

I had previously changed all the parts of the steering except the pump. Oh well, she wanted changed too after announcing with a puddle on the floor and no power steering. After I struggled with the tensioner, "This is stupid, why did Jeep do it this way?" they redeamed themselves with holes in the pulley to take the pump out. "This is great, why didn't Ford ever do it this way?"

New pump was good to go but out on the next drive and the temp was near the ketchup mark on the gauge. I didn't hear the electric fan kick on...

What idiot didn't hook the fan back up? Couldn't be me.

Adrianspeeder

All running good.

The reverse Carolina squat was making me angry though, so rack it up and we'll delete the bottom leaf.

Waaaayyyyy better.

So, New Mexico is wonky to tag a vehicle with because they tax the value of the vehicle when new. Had a trip come up to go to PA, so I went to get a plate there, but WHAT THE HELL did they change the plate design with this garbage!?! It's the Keystone state, not the Liberty Bell state. Trash!

Pretty much exactly how I want it now to cruze anywhere under 65mph and I have full confidence in the rig.

Adrianspeeder

Adrianspeeder