2002 Jeep Wrangler TJ-X
Ever since someone ran a red light and totaled out my Bronco, I've been looking for a new project daily driver. I thought hard about getting another Bronco, but after having that one for over 20 years, it just wouldn't be the same. I ran across this 2002 TJ and I rather liked it. It has pretty much sat for the last 10 years...putting on just 2,000 miles since then. The price was wasn't bad. The previous owners had done some modification to it, and the body looked fairly well taken care of...but the mechanicals need a lot of work. It's old enough that it is pretty straight forward to work on, and just has limited computers in it, so I'm good with doing the mechanical work. So I figured why not!
The evolution
When I bought it, it had several items already done to it. Below I've summarized what came from the factory, how those where when I bought it, and what I've changed it to. Each change I've highlighted in bold.
Factory | As I bought it | Where it is today | |
Engine | 4.0 liter straight 6 | 4.0 liter straight 6 | 4.0 liter straight 6 |
Transmission | |||
Transfer Case | |||
Rear Differential | Dana 35 | Dana 35 | Dana 35 |
Rear Axle Ratio | 3.07 - Open | ||
Front Differntial | Dana 30 | Dana 30 | Dana 30 |
Front Axle Ratio | 3.07 - Open | ||
Factory Options | Windows - Deep Tint Sunscreen
Door - Full Metal
Air Conditioning
Add-A-Trunk | Windows - Deep Tint SunscreenDoor - Full MetalAir Conditioning | Windows - Deep Tint SunscreenDoor - Full MetalAir Conditioning |
Emissions | US 50 States | US 50 States | US 50 States |
Radio | AM/FM Compact Disc | AM/FM/CD/Bluetooth | |
Top | MOPAR Soft Top | Smitttybilt Soft Top | Smitttybilt Soft Top |
Lift | None | 4" Suspension Lift | |
Tire Carrier | Tailgate | Rear Bumper | Heavy Duty Tailgate Mount |
Tires | |||
Wheels | |||
Seats | High Back Bucket Seats w/Passenger Side Flip Up | Rough Country Neoprene Seat Covers on Factory Seats | |
Front Bumper | Steel with winch | ||
Rear Bumper | Steel with tire mount | Steel with tire mount removed | |
Winch | None | MileMarker hydraulic winch | MileMarker hydraulic winch |
Center Console | Full length | Tuffy Security Console | |
Air Intake | Factory | Cold air intake | Factory |
Side protection | None | Rock Rails | Rock Rails |
Carpet | Full | Bedrug |
What Issues I've Found
As I've been driving the TJ around I've been seeing what I can find that is wrong with it. So this going to be my list of things to work on. I've split it up into three different categories. Safety issues are things that need to be fixed as soon as possible. Mechanical issues are things that need to be fixed to keep it running right. Convenience items are things that will make driving it that much better. As I find them, I'll keep adding them to the list, and as I fix them I'll cross them out. As it is right now, here is the list:
Safety Issues
- The rear swing out tire carrier does not sit correct and is difficult to latch
- Shocks do not all match...two different brands and three different models. Not all shocks are tight, so issues with mounts
- Interior lights do not work (not the dash ones, they are fine, rather the lights when a door is open)
- Airbag light is on
- It would start in gear without the clutch being pushed in
- Side mirrors are mounted on the A Pillars, so for doors off driving, rather than on the doors. So they have very poor visibility
- Track bar bolts wrong size and well worn
- Front drivers caliper locking up when braking
Mechanical Issues
- Winch does not appear to work
- Loud clunking / rattle coming from back
- Engine running a cold air intake, so not all that safe for water crossings
- I have a copy of the CarFax and the dealers work done to it, but there is a fair amount of maintenance that isn't listed so unsure when or if it has been done
- O2 sensors not all working
- Speaker bar has several speakers not working
- Speaker bar has right and left channels reversed
Convenience Items
- The cup holders are missing the rubber inserts, and any cup in them interfers with the shifter
- It needs a cell phone mount
- The radio is an AM/FM/Bluetooth, but I would like one that can run Android Auto
- I'd like to add a steering box skid plate...it isn't overly protected right now
- Front and rear bumpers are not my style
- Needs to be some overhead storage added
- Needs a security box / instatrunk
what has gone into it
Without knowing the entire history of the Jeep I decided to go through and catch it up on all the maintenance. That way I know what level it is at now and will know when the next services will be due. While doing that I run into things that need to be repaired, so I've gone ahead and done that as I go along. And there are somethings I want to do to it to make it better / more useful / etc. So here I'm tracking everything that I've put into it.
Maintenance Items | Repair Items | Enhancements |
Dana 30 Gasket
Dana 35 Gasket
Valvoline Differential Fluid | US Standard Dana 35 Spider Gear Set | Red Hound CB Antenna Mount |
MOPAR Oil Filter | Inner Shift Boot
Outer Shift Boot
Shift Boot Retainer Bezel
5 Speed Shifter Knob | 2003-2006 Style Side Mirrors
Mirror Mounting Bolts |
NGK 3459 Spark Plugs | 7219 Light Bulbs (Solder In) | JECar Cell Phone Holder |
Standard Motor UF-296 Ignition Coil | Radio Antenna Mount Base
7" Radio Antenna | Soft Top Window Storage Bag |
Valvoline Manual Transmission Fluid | Bank 2/2 O2 Sensor | FieryRed 3/8" Synthetic Winch Line
Synthetic Rope Fairlead
Winch Hook |
ValvolineTransfer Case Fluid | Rough Country Rear Adjustable Track Bar
Grade 10.9 Mounting Bolts | Hooke Road Tailgate Reinforcement
Heavy Duty Spare Tire Carrier |
3-Way Speaker Crossover | Fuel Cap w/Tether | |
Quadratec Hydro 7 Shocks
Grade 10.9 Mounting Bolts | Tuffy Cup Holder
Tuffy Keys | |
Dorman Door Pin Kits | Military style battery terminals | |
Rough Country 3-Pin Winch Remote | Drivers side rear storage bag | |
Aluminum Battery Hold Down | Single Din Head Unit | |
Courtesy Light Harness (Passengers Side) | ||
Powerstop front brakes, rotors and calipers |