Why did they do that?

Z

Zef

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Joined
Nov 24, 2022
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27
Location
Chandler, AZ
Hi, I'm doing some maintenance on a new to me 2004 X.

So far I've encountered a few head scratching "Why did they do that?" engineering/design decisions.

I figured I'd start a list just for fun. I'll update it as I go along. If one already exists just point me to it and I'll move this there.

1. Ignition coil connector. Just why? Placement and operation.
2. Front sway bar end links top nuts. The one ball joint extension grabbed onto the bar without even trying. With the other the ball joint kept turning with the nut. What an adventure this turned into. Solved using a screwdriver wedged between bar and nut.
3. Front sway bar bushing bracket bolts. I assume there must be a way to easily remove the grill to get to the rear bolts. But I just sat there with my 15mm open box and slowly backed it out.
4. No drain holes in diff covers.
5. Not done yet, but I'm hazarding a prediction: Rear track bar Torx (?!??) bolt.
6.
 
Zef said:
Hi, I'm doing some maintenance on a new to me 2004 X.

So far I've encountered a few head scratching "Why did they do that?" engineering/design decisions.

I figured I'd start a list just for fun. I'll update it as I go along. If one already exists just point me to it and I'll move this there.

1. Ignition coil connector. Just why? Placement and operation.
Click to expand...
I've wondered if they used a coil rail from another rig for that one. Pretty much a PITA.
Zef said:
2. Front sway bar end links top nuts. The one ball joint extension grabbed onto the bar without even trying. With the other the ball joint kept turning with the nut. What an adventure this turned into. Solved using a screwdriver wedged between bar and nut.
Click to expand...
Likely a boogered thread on the nut or stud. Best to run those all the way on by hand first to check.
Zef said:
3. Front sway bar bushing bracket bolts. I assume there must be a way to easily remove the grill to get to the rear bolts. But I just sat there with my 15mm open box and slowly backed it out.
Click to expand...
We routinely remove those with a short socket on a wobble extension. We also routinely have to do it like you did when the grill is more forward than most.
Zef said:
4. No drain holes in diff covers.
Click to expand...
Nor should there be since that isn't the low point.
Zef said:
5. Not done yet, but I'm hazarding a prediction: Rear track bar Torx (?!??) bolt.
Click to expand...
Pull the tires, put jack stands under the rear bumper, lower the axle. Access always make the job easier.
Zef said:
6.
Click to expand...
One of the more irritating is the 05-06 fuel pump connector is on the pump and the harness isn't always long enough to disconnect it with the tank very low. The fuel line to the pump has caused more than a few to buy a new pump when they lower too far and snap the plastic fitting off.
 
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The ignition coil electrical connector is hard enough to reach as is, then some idiot ziptied it to a wiring harness on the firewall of my tj. 🤯
 
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