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https://wranglertjforum.com/threads/jeep-wrangler-tj-factory-service-manuals-fsm-technical-documentation.4618/

As for the engine running LEAN; you should be able to check that with the trim specs on fuel injectors loading. Do you have a crack or leak in the exhaust header/manifold ? My 1998 XJ 4.0L had a crack in the exhaust header where the tubes joined causing an exhaust leak (audible ticking under...

The gear housing has numbers referring to the orientation of the speed sensor body to the tcase housing depending upon the number of teeth for the speedometer gear. As JB stated above; ensure the gear and sensor are engaged properly.

I understand that you have changed almost everything in the cooling system, but I donot see that you have replaced the thermostat with a GOOD quality thermostat such as STANT nor do a see that you performed a thorough flush of the system... Might be worth looking into...

Noticed the A/C high pressure line service port fitting is missing it's protective cap; I would check the low pressure line service port fitting to see if it's also missing its protective cap.

The biggest tire depends upon the Offset or Backspacing of the rims..... Probably around a 31" (245/75-16) tire IF you are not installing spacers or longer bumpstops.

Have someone assist you by turning the steering wheel and then looking at the steering shaft that is attached to the steering box; you can judge by how much the steering wheel turns before the steering shaft turns. You can examine the steering coupling for play while the steering wheel is turned.

Sounds like a caster problem or bad steering shaft coupler...

Could you be a little more descriptive with the word UNSTABLE ? Front end vibrations, drifting steering, death wobble ?

Would it be possible to fabricate one from steel and tack weld a couple nuts on the backing plate ?

Since the PO replaced the HVAC control unit I would make sure the hoses are connected properly, the blend door is operating properly and the actuator motors are operating properly along with verifying there are no vacuum leaks in the A/C controls.

Did you leave the front plastic fitting on the valve cover capped off with a blue rag OR was that picture taken while fabricating the cowl cold air ? The front fitting needs to be attached to the intake tube to remove vapors and fumes.

In the Philippines I installed a window A/C and mounted a large oscillating fan on the wall. Its the only way I can tolerate working in the garage.

YES.... During the day we had mid 40s on quite a few occasions, but normally mid 50s to low 60s.

Several years ago while visiting the Philippines I needed to order a radiator for a '93 Toyota LC which required ordering from Japan, but I was pleasantly surprised that the box arrived in 4 days. Working in 95* temperatures with 90% RH is no fun at all..... Drains your energy really quick....

In JAX this winter I observed the temperature of 33* on several occasions.

Jerry, I went thru the same thing when I moved to JAX a couple years ago. At this moment I am in the Philippines trying to work on my '93 Toyota LC p/u and I can only deal with a couple hours before going in for a cool down period and a beverage.

What would a trip to the Philippines be without admiring the local scenery.

PM'd you.

I enjoy visiting as often as I can, but I have to admit that working on your vehicle in this heat and humidity can be difficult; trying to locate parts will almost always require having them shipped in. A couple years ago I had to order a new radiator since the local shops were having a problem...