Project Daily Drive 1983 Wagoneer Work Log

[Achilles]

The switch plunger is to long and has to be pushed further down in the switch body. If you put it on out of the box it is to long and will be broken when you close the door.

[Achilles]

I pulled the dash switch and started preparing for the new switch.



New Switch



I removed the Broken OEM switch and cut the bracket to allow the switch that came with the harness to fit.



This is my temp solution for keeping the dash switch in place.



The backer washer



Sorry for out of focus picture. Installed.



I plan to make something that looks a little better than the washer for outside part of the dash.

Back to the tailgate. here is a picture of the glass channel in the tailgate.



Old wiring secured along with the extended safety switch wiring with the yellow connectors .



Here is were it came to a screeching, grinding halt. I just figured out that something was wrong with the regulator motor.



To Be Continued!!!!!!!!!!

[Achilles]

This is how I fixed the Tailgate regulator motor!!!!!

Motor would not work under weight of window. When I opened the motor up it looked like black chunky peanut butter. I did a lot of research and did not find any parts to fix my motor but found 1 post with mentioned of what was probably wrong with it. I found a part which I thought would fix it but after purchasing it found out it was to small to work in this application.







Found out that I was on the right track with this part except that it was to small.






There was a faint trace of where the original plug had been. I placed a dime in and it was the same size as the mark in the gear. I went to lowes to see what I could find.

I came up with these, as per the thread I found on here. http://www.ifsja.org/forums/vb/showthread.php?t=21298





If you take the motor apart and separate the nylon gear from the metal, you will see exactly where they go. They were a tad bit bigger than I expected but the gear fit back together snugly and did not slip.

Use plenty of grease upon reassembly.



I am sorry I did not take a picture of the tare down and reassembly, but I was a little frustrated and not sure if it was going to work. When I reassembled, it worked like a charm. I did not even consider taking it back apart for pictures. Some people advocated using the appropriate size nut in place of the plug, I feel that if it binds or have an issue it would strip the big nylon gear and I do not know where to get a replacement. I think the nylon spacers would break just like the original plugs and not harm the gears. This hole fix was under $4.00 us. If you have any question ask me.

[Achilles]

Installed the inner and outer tailgate wipes.



They fit well.



Mounted the Serehill control board for the tailgate wiring harness





Now I just have to dig the access cover out of wherever I stashed it and mount it.

[SJTD]

Are dose some sort of cushion between the gear and the output shaft? I wonder if I should open mine up for a look.

Seems to me I might have done it before I let it sit for 15 years.

Nice to know the wipes fit. I just ordered some.

[Achilles]

They mesh the big nylon gear to the output shaft. You will not hurt it by opening it. I thoroughly cleaned it up and flushed the worm gear area with break cleaner. The only other thing you need is grease. Bj's has gotten a lot of my cash here lately.

[Achilles]

Since may 13th the weather has been really bad around here, since I work out side I took a break and went on a trip with my wife.






Spent 4 days here........


Arrived back home and forgot I left the shop such a mess.... Had to get it cleaned up.

[Achilles]

The weather has still been bad off and on, severe thunderstorms etc.... Texas now has a monsoon season. I work on the Wagoneer when I can and when weather permits me.

Connected tailgate window power and ground to the resettable breaker for the last time. Added two other resettable breakers for up coming projects.




I found the rears access panel and reinstalled it.



I also put the new latch bumpers on.



I also swapped out the old light switch for a new one and replaced both the light switch and windshield wiper knobs.



I pulled the gauge cluster again to start work on Ammeter bypass.



I started removing tape from harness to trace the yellow and red wire.



To Be Continued........................

[DarkMonohue]

Wow, you're really tearing it up! Keep the updates coming.

[SJTD]

I seem to recall there being some bumpers in the body too. I haven't dug into the removed parts to look. Are the ones in the body the same as these?

I also put the new latch bumpers on.

[Achilles]

I replaced the ones in the body first. Then I ordered a second set of them for the tailgate. The ones in the tailgate are actually smaller but the body bumpers worked just fine.

[Achilles]

Continue working on the ammeter bypass. Cut off enough of the wrap to find the big splice.



Had a hard time locating it because it was covered with duct tape instead of electrical tape.



Red wire Removed.



I figured the duct tape was there for a reason, so I put it back. Just kidding there is electrical tape underneath.



Fuseable link connected to red wire from two prong alternator plug and yellow wire from inside the cab.







Crimped a eyelet on the yellow and extended the red wire. Connected Yellow to one of the resettable breakers.



Eyelet placed on red wire from 2 prong alternator plug and attached to charge side of solenoid.



Eyelet crimped on extended red wire from post on alternator and attached to other Breaker.



Jumper wire to charge side of solenoid added fro red wire from alternator post breaker. I have not done this for the yellow wire. I will do it once I get the Aux fuse panel connected under the dash.



Crap the post on the alternator broke lose when I was removing the
bolt from it. Out comes the alternator.



Today's Carnage:

[Achilles]

Ran to the parts store last night and got a replacement alternator. It is loosely mounted.



I made a 4 gauge charging wire out of materials I had laying around. I crimped and heat shrunk both lugs.



Everything Buttoned up and new charge wire connected to alternator.



New charge wire connected to Charge side of solenoid.



Alternator charging battery like it is suppose to.



Successful ammeter bypass.......... On to the next thing. (The yellow wire has been rerouted inside the cab but no connected to power under the hood until aux fuse panel is mounted under the dash.)

[mdcptman]

This is an awesome build thread. Im really enjoying it. Especially the pictures! Keep it up!

[Achilles]

Had to clean the shop up it has become a mess again.



The rain is gone and the heat has set in.



New equipment added to the shop.





Back to the Jeep tomorrow.