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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

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