Project Daily Drive 1983 Wagoneer Work Log

[Achilles]

Front Dana 44 service and new Breather/vent hose install.



Gears are good, looks like the PO used the same clear house silicone to seal the diff cover as he did on the transfer case. Minimal sludge in bottom but fluid was way darker than the rear axle. You can se a string of the silicone hanging down from the top on the left side of the picture.



This axle has 3.31 gears in it.



All buttoned back up.



Added the gear oil.



Removed old and installed new breather / vent tube. Wow, This is dust season in Texas and it gets every where. Time to wash the motor and engine compartment.



Made it a tad bit longer, so i can place it where I want later.



Today's carnage.




Beware the gasket for a front Dana 44 that most parts stores will sell you is not the one you need for the 83 and up with the vacuum disconnect axle. I had to use Ultra Black RTV which I had on hand. I have a Dana 44 gasket if anyone need it at a fair price.

[Achilles]

Steering Stabilizer

The steering stabilizer plate on my wagoneer has been broke since I have owned it. I purchased one from a member on this board. Cleaned it up, painted it and put it away. I was reluctant to mess with the u bolts and axle because it has been out of my comfort zone. After discussing it in a thread earlier in the week I decided what the heck I am just going to do it and take pictures so I can get it back together right. When I let the jack down after disconnecting everything and putting a jack stand under the frame; I flipped when the axle sunk almost to the ground. I took a deep breath and started working.

Broken steering stabilizer and plate.





You can just see the broken connector plate under the perch.



I had soaked the U bolts and stabilizer bolts in PB Blaster for the last couple of days. The stabilizer came off easy.

The u bolts fought a little and then came off. I disconnected the shock and the sway bar end link, placed a jack stand to support the frame. Lowered the jack. The spring sagged more than I expected it to. I got the jack under the axle tube and it separated from the springs.





Broken stabilizer plate.



What have I done. Deep Breath.



Today's Parts



Put the plate in and reversed everything I had done before this. and got the u bolts back in and everything sort of lined back up.



Buttoned back up.



Everything installed!!!!!



Today's Carnage



Not to bad for the first time doing this.

[Achilles]

Why these rigs are so awesome!!!!!!!!!!!!!!!

Owning one of these rigs is not cheap and can be super frustrating at times but it is awesome entertainment. Even a bit addicting. It is weird how they almost become like family mascots or almost like pets. My oldest was home from college this past weekend and came out back to see me. You should of seen the smile on her face when she realized that the Wagoneer was running. Even my wife who hates outside with a passion came out to see Achilles. She even helped me remove the tailgate regulator and glass after I had a Jeep induced mini melt down. We had bad weather the past couple of days, and I could not get anything done since I work outside. More Updates coning soon.

[Achilles]

Today's Parts



Getting ready to drain antifreeze.



Draining



I popped the thermostat out in it was a 160 degrees F thermostat. What the heck and why was it in here. no wonder engine would never come up to temp.



All laid out and ready to install.




Only had one minor problem geting the the heater hose that connects to the water pump back on. I partially disassemble the alternator bracket. to get it on and tighten the hose clamp. All finished up with hoses.



Belts on.



Today's Carnage

[Achilles]

Changed the oil to 15W-40 Today. Decided to give it a try. The 10W-40 looked a little thin.

Today's Carnage

[SIUADOG]

Loving this write up, especially the carnage photos. A big bag of trash (and no ruined parts) at the end of the day gives a feeling of accomplishment.

[Achilles]

I put a quart of Rislone in the oil.

I decided to bolt the drivers side seat back in so that it would not be quite as precarious moving the waggy around.



I decided that I need to adjust the power seat. I crawled in to the back to make sure all the tailgate wiring were still disconnected before I put the breaker back in. I decided since I was back there I would take a drill battery and lower the window. I touched the wire to the battery and it went a third of the way down and stopped. Crap, now I am side tracked. It would not go up or down. Off came the latch cover and key switch body.



I wedged my hands in behind the regulator and took the 3 bolts out of the motor with a 7/16 wrench. I pushed the window down and removed those dreadful clips. After having a melt down. My wife helped me get the window and regulator out.



Off comes the tailgate switch. Yep, it is broken for sure.



What in the Heck have I done.



I discover as I am cleaning up the regulator that I am possibly missing three stand offs. After another mini melt down. I realize there is no way I am getting this back together today. I have to try and locate the stand offs and dig the parts I ordered from BJ'S for the tailgate out of storage. I have all the seals and parts, but had not planned to do this until after I had the waggy running solid, safe, Inspected and registered. I vacuumed all the junk out of the tailgate and washed it out with a hose. I lubricated the gate mechanisms so it would close properly. I pulled the waggy back to its storage space and went and purchased a bigger tarp to cover it up since it no longer had a rear window.

Today's Carnage



Unintentional Carnage: 1 rear tailgate window



And as luck would have it we have had thunderstorms for the past three days. I just had to move the power seat!!!

To be continued.

[Achilles]

Thanks for coming along on the ride. It is my first attempt at doing something like this so I am learning as I go and loving every minuet of it.

Loving this write up, especially the carnage photos. A big bag of trash (and no ruined parts) at the end of the day gives a feeling of accomplishment.

[DieselSJ]

Great idea on fiberglassing the visor cups. I'm going to give that a shot.

[Achilles]

Still working on tailgate and window.

Today's Parts!!!



Started by removing upper window track in the body.



All gone



This is what was left of it. Over 2/3 of it was missing.




New one installed.



Time to remove the body sill. It was in good shape but really compressed.

[Achilles]

Still working on tailgate and window.

Today's Parts!!!



Started by removing upper window track in the body.



All gone



This is what was left of it. Over 2/3 of it was missing.




New one installed.



Time to remove the body sill. It was in good shape but really compressed.




Also remove these two small square bumpers.



Bumpers and seals off.



New one installed.






Old lisc plate light and replacement.





To BE Continued!!!!!

[Achilles]

Decided to fix the front passenger and driver side door jamb switch.



Modified switch.



Installed!!!

[Achilles]

Now on to the tailgate inner slide channels. The old ones were really eaten up and hardly had any felt left on them. Straight forward easy install.



Testing the safety switch after cleaning.



Back in.

[Achilles]

Starting the Tailgate harness install.





New Switch is in.




Installed with new gasket.



Back together.



Once again I have some pictures that did not come out well. Here is the only one of the tailgate window channel refurbish and refinished.






To be continued.

[SJTD]

What was the mod to the door jamb switch? I've read that available switches don't fit. Haven't started looking yet.

What's the box on the plate next to the relays for the window?

Looks like you need a cover for the tailgate key switch too.