Is there a particular year of the LJ that is best to build?

My post said both models- they are both a CEL waiting to happen - mainly because the emissions are designed to be replaced and most of us don’t want to bite the bullet and buy 4 sensors and pre cats and do it right is one reason. They have a finite lifespan.
I was already thinking of a custom wiring harness. Maybe a Paynless or some other. When it gets to that part of the build.
 
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If you're going with a V8 swap and your other outlined build plans it won't really matter. I'd find the cleanest one and start there. There were roughly 29k more 05/06 LJ's produced so it's easier to find those yearsThis is what I'm planning on. It will be a v8 because that's what she wants. 351W and 10R80 trans. Gotta keep mama happy.
 
You'd think they would be, but Chrysler is among the worst with little changes every couple years trying to find ways to save a few bucks per part.

05 got a new fuel tank (not sure if they also changed the evap emission system). A moving plastic part in the tank swells up and gets stuck, the only fix is to drop the tank and sand the part down a bit. It's free from a parts standpoint but it takes effort dropping the tank.

05 got a new pcm. Automatics previously had a standalone transmission module, starting in 05 they integrated it in the PCM. They changed some sensors, including the crank position sensor, which also got a new location, and the cam position sensor, which got a new housing and oil pump drive assembly. It's difficult to nail down the actual failure rate but there were a number of examples with fairly low mileage of the OPDA locking up, shredding the drive gear or shearing off and stopping the oil supply to a running engine. My hunch is this might be an issue where if they were gonna fail, they fail fairly early. It doesn't seem to come up that much anymore but it was all over the forums in 2010. They also had some issues causing automatics to throw a transmission code and a hard 1-2 shift when cold, and I think some other codes that aren't real and won't go away. The answer to that one is a new pcm, about $1200 last I looked, but at least there's a fix.

05 got a new manual transmission. Search nsg370 on this forum and you'll find out what many of us think about it. I'm in the process of swapping mine out for the 5 speed used in pre-2000 TJs.

I personally have had the fuel tank issue on an 05 and an 06, had the OPDA issue on an 05 (caught early) and had problems with the transmission on an 06. I think TJs peaked in 1999 and again in 2004, but damn I love an LJ and I like to shift, so here I am.
I'll replace the tank for a fuel cell and the Holley Sniper EFI.

If I still drove I'd have a stick too.
 
If you're doing a full drivetrain swap, it doesn't really matter. I haven't seen it mentioned, but Rubicon's were not available in 04. So... For your purposes, I'd go 04 and avoid the potential known issues.
That's the plan Mike. Engine, transmission, transfercase, drive shafts, and axles.
 
That's the plan Mike. Engine, transmission, transfercase, drive shafts, and axles.
If you're replacing all that and getting a fuel cell then you're getting rid of all the 05-06 issues anyway. Take your pick of the 2.5 years of LJ production and carry on.
 
If you're replacing all that and getting a fuel cell then you're getting rid of all the 05-06 issues anyway. Take your pick of the 2.5 years of LJ production and carry on.
Thanks Joe. Yes, basically just the body will be original when all is said and done. I'm waiting on US Shift to work out the kinks with their stand alone controller for the 10R80. They have one for the 6R80 and it increases mileage greatly and it is still something that I'm considering. Everything under the hood and body will be new.
 
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Easily fixed with an LS swap
LOL The usual answer for a V8 swap. I have no problem with the LS swap but I'm a Ford man.

After we get an LJ my wife wants to drive and play around in it for a little while before we start doing the heavy mods. We'll do things like upgrading the headlights, taillights, lightbar, stereo, seats, etc. first.

If it was my build I'd have a CJ8 on a LJ frame.
 
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I don’t quite understand why you would ask the first question if you’re taking everything out and replacing it anyways…
Obviously the question was asked because the differences weren't known. The frames, brakes, steering, body or any number of other things could have been different and that's why the question was asked.
 
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Is there a particular year of the LJ that is best to build?
Is there a difference in electronics, buses, and any other things in the '04-06s?
I'd go strictly 2004, there are issues with 2005-6 models that don't exist with the 2004. Fixable or not, I'd still choose the 2004. Both problems cause downtime and require aftermarket parts to fix. I'd rather have a model year, 2004, that absolutely does not have either of those two potential issues.
 
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Obviously the question was asked because the differences weren't known. The frames, brakes, steering, body or any number of other things could have been different and that's why the question was asked.
Thanks Paul.

Exactly and I want information from people that have experience with these wonderful Jeeps. I've never had my hands ona LJ, TJs I have. Since I'm blind and can't view pictures it's critical to me to get descriptions and all the information that I can before starting a project.

Now Broncos I know inside and out. At least '66-'79.

I can't go out and visit Jeep shows unless my wife takes me. Plus my guide dog states that, "her job is to guide me somewhere safely not to describe silly ass pictures to me". LOL

We don't get to many Jeep meets because she's a weekend night nurse so unless it's womewhere really close I have to hitch a ride.

Once the wrench turning I shouldn't need but a little help except for many, many beers, a few shots of tequila, blood, sweat, tears and so many cusswords.
 
I'd go strictly 2004, there are issues with 2005-6 models that don't exist with the 2004. Fixable or not, I'd still choose the 2004. Both problems cause downtime and require aftermarket parts to fix. I'd rather have a model year, 2004, that absolutely does not have either of those two potential issues.
I guess that means you'll be over to help us swap in a new cam into this 04 TJ Unlimited because the camshaft synchronizer locked up and bent the cam, right? I've worked on and built far more 05 and 06's than I have 03-04's and I've yet to need to do any engine work on them. The two known issues are simple, OPDA and PCM. Crown has as many OPDA's as you would ever need and Mark has as many PCM's as you would ever need or want to buy.

Once you get past those two small things, the rest is the same and does not matter at all especially since he is dumping the whole drivetrain anyway.
 
Thanks everyone for helping.I'm interesting in reading threads about LJ builds and mods. Suggestions welcomed. I've been reading many different threads like dual batteries, lifts. etc. and love all the information that I'm gaining.

I guess that means you'll be over to help us swap in a new cam into this 04 TJ Unlimited because the camshaft synchronizer locked up and bent the cam, right? I've worked on and built far more 05 and 06's than I have 03-04's and I've yet to need to do any engine work on them. The two known issues are simple, OPDA and PCM. Crown has as many OPDA's as you would ever need and Mark has as many PCM's as you would ever need or want to buy.

Once you get past those two small things, the rest is the same and does not matter at all especially since he is dumping the whole drivetrain anyway.
I guess that means you'll be over to help us swap in a new cam into this 04 TJ Unlimited because the camshaft synchronizer locked up and bent the cam, right? I've worked on and built far more 05 and 06's than I have 03-04's and I've yet to need to do any engine work on them. The two known issues are simple, OPDA and PCM. Crown has as many OPDA's as you would ever need and Mark has as many PCM's as you would ever need or want to buy.

Once you get past those two small things, the rest is the same and does not matter at all especially since he is dumping the whole drivetrain anyway.
Thank you mrblaine. It just needs to run enough for my wife to get use to driving and playing with it, then the major mods begin.
 
I have an '05 LJR with the dreaded infamous NSG370 6 speed manual. I have no issue with CELs. I addressed the OPDA issue as preventive maintenance. I did have the reverse issue with my NSG370 that causes many to replace it with a 5 speed. I replaced mine with a freshly rebuilt NSG370 that has no issues whatsoever at least not yet. I'm confident I won't see the reverse issue again FWIW.

I did recently get a CEL for an O2 sensor, with about 110K miles on it. I replaced all 4 with the recommended NTK sensors. CEL is gone and it runs perfect. Seems to idle a little smoother than before but probably my imagination. O2 sensor fault is a very typical failure that occurs eventually in any vehicle that has O2 sensors. I think every vehicle I've owned with O2 sensors and >100K miles has had a sensor go bad. Hondas, Chevy, Jeep, doesn't matter.

My steering box also started leaking not too long ago. Not sure what years have this box but these steering boxes have a poor reputation. That problem could have been resolved (for a while) with a parts store rebuilt unit. However, I opted for what I hope to be a more durable fix with hydro assist options, the PSC big bore steering box. Pricy but should solve the issue permanently.

IMO, the horror stories about the '05 and '06 model years are WAY overblown. Most of those stories come from people who have never owned one. I wanted a LJR with a manual transmission so choices were severely limited as to the year. I knew about the few well-known issues and they seemed easily solvable. So far they have been easily resolved.

I have no regrets and have never wished I picked something different. The repairs done to keep it running its best seem pretty consistent with what I would expect on any 17 year old vehicle, especially when you consider the type of use it gets off road.

YMMV.
 
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I opted for what I hope to be a more durable fix with hydro assist options, the PSC big bore steering box. Pricy but should solve the issue permanently.
Did you switch yet? I’ve been thinking of doing the same, how’s the on center feel? I don’t plan on running an assist just want more precise steering.

I never understood the hate for jeeps steering til I replaced my 99 for an 05. Mine doesn’t leak yet but the deadzone is half as bad as my 47, this causes quite the wandering on the highway. My 99 box had almost no deadzone and 60k more miles.
 
03-06 for that piece of shit. Although I know of some with high mileage, most are crap by 100,000 miles or so.

Blaine, what wears out in these steering boxes in your experience? And given this is the case in higher mileage rigs, would you recommend a PSC box setup if one is looking for longevity ? I know that you have mentioned in the past that given the cost/complexity and the care needed for your full PSC setup, it is not for everyone, but given the very limited support for the early gear box in the TJ, I would like to learn if it is worth replacing just the steering box if the need arises after 100k.