So another month passed and there is some progress with Wagoneer.
This month I finally got to suspension and steering, started with easy things like replacing old torn rag joint and rotten sway bar bushings. Also did axle vent tubes - front one was good but was not fixed to anything and was 1 inch away from being eaten by fan
Rear axle vent hose was torn and was hanging over track bar.
On Memorial Day weekend I took Jeep on a road trip for a first time.
Not too big of a trip (450ish miles in total), but way more than I ever driven it since I got it. Jeep did really good and surprised me with highway gas mileage - 13-15 mpg! I expected maybe 10-11 based on what I was getting before, so that was nice, especially with low gas prices
Also realized that I really need new shocks and working AC if I want to go on more road trips
Ordered a set of Bilstein 4600 shocks
Installation was not as easy as I thought - bushings on Bilsteins are a bit wider than on old ones (based on 32164 stamped on old ones I believe them to be Monroe Monro-matics). Also replaced u-joints in rear driveshaft as they were pretty worn out and put a new steering stabilizer in.
While installing shocks I found a oil leak from rear axle - when I pulled the axle shaft out it turned out that not only the seal was bad but bearing itself was getting really wobbly (explains vibrations I was getting when going over 60 mph). Since you need to remove old bearing and retainer to get to the seal I'd consider it "2 birds, 1 stone" situation
Hardest part here was finding local machine or mechanic shop that would press new stuff on the shaft without charging me for 2 hours of labor
Another discovery happened when I took out the spare - it looks like the original one and it was never mounted.
Still holds air and doesn't have any cracks, but I'll probably replace it with something newer than 32 year old tire
Took Jeep on a drive after doing all that and, like usual, night and day difference! Bilsteins are amazing - not too stiff, but no nose dives or excessive body roll when turning. Overall ride quality has improved a lot
Replaced the rest of window wipes - I did outer ones couple month ago, now it was turn for inner ones. Had to get another tool for getting them out because my old one (I think I got it from TGW, but not sure) was too thick and wouldn't work for inner wipes (worked good for outer though). For inner I got Lisle 35150 - it is thinner and actually fits on the inside side of the glass. So now I have all new wipes - windows and tailgate, inner and outer.
Recently I came across USB changer and power outlet module while ordering some relays on waytek. Cigarette lighter in the ashtray is not very convenient and I use it for it's primary purpose anyway, plus sometimes I need to change 2 or more devices. So got this module and started to think how and where should I mount it
Wired and printed a box for it
It is mounted under AC duct in the middle. There is a cover held by 2 screws on the duct which I copied (I try to keep original parts intact if I can) and used it to mount the box. Both outlets are wired through flag fuse to battery feed. Here's how it looks when installed:
Another convenience feature that Jeep recently received is keyless entry
88 didn't have wiring for it (I think Chrysler started offering it in 89 with overhead console), but since I already "relayed" everything I could it's a lot of work. Got CMD-4000 module from Dakota Digital - it is a nice module, offers 7 channels with built-in relays for channel 1 and 2. I could probably get away with cheaper chinese modules from amazon, but wanted to get something with good quality and sort of "period correct" remotes, hence the module from DD. For my application I'm using 4 channels (1 lock, 2 unlock, 3 rolls up tailgate window, 4 rolls it down) and built a 4 relay box to connect it to factory wiring
Overall install is relatively easy, except splicing into power lock wiring - it is very tight under dash and had to strip wires and crimp connectors on them. I tucked both modules away inside the dash on drivers side and used sticky tape to mount antenna to AC duct (I'll probably print some kind of holders for it as I need to remove the tape every time I'm dropping drivers side AC duct). I was thinking about using channel 5 for horn, but decided that it's not that hard to find a Wagoneer in your typical parking lot
After almost 2 month of waiting headliner from BJs finally arrived. Put it in on Sunday (spent the whole day putting it and all the trim on) - looks very nice even though I messed up couple things. Has a very strong glue smell, but hopefully it will go away over few days.
Two things are in work now - AC and new armrest/center console. Much to my surprise AC is charged and works, only issue it has is a blown motor resistor and rusted blower motor that won't turn. Already got the resistor (they are identical with heater resistor) and now waiting for blower motor to arrive.
For armrest I've found one from 90s Buick Roadmaster that few members here and on ifsja have successfully installed. It is almost a perfect fit for FSJ, has 2 cup holders and a lot of storage area - FSJs lack both
Was looking on ebay ($200, whew) but then scored one from pick-n-pull for just $20ish. It's going to be reupholstered, so far I was cleaning it and working on mount plates and relocating the stopper pin so it would work with FSJ seats