Novak Conversions Jeep Wrangler TJ radiator

Going from 4 inch heels to original slippers (posting as I go)

2005 wrangler X ?

There And Back Again
Original poster
Supporting Member
Joined
Oct 10, 2024
Messages
172
Location
Maine
Ist-Paying to be a Member was well worth it
2cd-Gotta Like all the Folks here WHO HELP THE HELPLESS
3rd-surfing late one night on here I found THIS
https://wranglertjforum.com/threads/stock-spring-swap-walk-thru-with-pics.12655/
it was like hitting a Gold MINE for Me

My History (short version)
im old and decrepit, beat the hell out of my body all my life with a life of Hard physical work THAT I LOVED
3 heart stints,3 heart attacks,chineese 20yr warranty tubing with "T's" from one artery to the other just above my old tired weener
ticking with 70 percent of my squirrels 30 percent turned to stone,severe asthma from smoking and all the fumes ive inhaled all my life
all my joints and parts of my spine have the Death wobble,theres no grease left in them I live for tylinol, I dont do pain meds im allergic to those AND X-Wives qit that habbit after number "3" oh ya and long and short term memory loss from a hit to the head--where was I,I did NOT do that ,ok maybe I did DAMMED IF I KNOW :)
Grew up with a mechanic who started in the 60's buying fixing up and selling cars and ended up buying and selling Showroom/museum quality cars
My first job was days on end sorting huge piles of nuts,bolts, washers,screws into buckets (I was 4 and little did i know it was to keep me out of his hair as he was working
I DID learn alot of "COOL" words not to be said in public) As I grew up He taught me invaluable lessons about people, wrenchin on auto's, and LIFE
,
My First Jeep (my dad owned quite a few) was a 90yj with a 4 almost dead squirrels barely hanging onto life, I drove it home (200 miles, bug spraying with 6 quarts of oil)
stripped it ALL to pieces, every piece that had a bolt or screw in it then rebuilt it and welded up my own rock-gear bumpers ect
I was 30sumptin with a wife and kids, One of my Daughters was into being with her dad, I passed along to her what MY DAD passed onto me
The jeep I have now will go to HER or Her/My Granddaughter

Now that ive wasted 2 or five minutes of your time (i have no idea if your a speed reader or not)
Ill get to the Topic
Ill be Posting pics and words about my Jeeps journey upon the Jacks (probably going nowhere NOT Fast :) )
IF I go Missing for a week or more, well GODS beckoned me and i put it in 4W HIGH drive and left the building

Day-1 nov-10
cleaned Garage drove jeep in nose first, jacked up enough to remove tires without having to drop them off the studs
jacked it up until I could sit on a milk crate and get my swollen head (i can do this, I think i can-i know i can i know i can)
got the upper bolts off the shocks, and bolts out of the front sway bar links DAM if i did NOT have a T55 I know I used to-fricken thing snuck off somewhere
the size smaller works as i did some praying to the NON stripper
 
Sipping my Coffee at 1225AM woke up feeling like i got runover and dragged by a mudrunnin jeep :)
so im posting some pics and going over the install link/"HOW TO" i saved and writing notes

everything was going good, better than expected, except for all that sticky crap (fluidfilm) I sprayed all over everything to keep it from rusting
im wearing it everywhere
shocks, passenger side was easy, swore at getting up into the bottom nuts top wrenched right off with the vice grips
drivers side, I got to comfortable, top nut kept spinning the shaft in the vice grips, but a few more choice words and some pizzle-piss (Dads name for WD40 and Blaster)and it started out
lower nuts backed right out AFTER i figured out i had the impact on "TIGHTEN" and not "LOOSEN". DU :)

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went to the pitman arm I went to the local(20 mile ride) Harbor freight and bought the joint puller that was recommended on the "HELP" topic
while tightening it it was doing nothing, and i could see it bending on the arm, sitting there looking at it, the EVIL little bird on my shoulder said to GOFORIT
so i gave it another wrenching turn and shit my pants as the dam thing exploded, I missed it because I had my eyes shut Praying, but I DID HEAR IT-Like a DAM 10Ga. going off with a metallic ring of the dinger
I still had all "MY" parts and pieces and all of the jeep was still there but when it let go it sent the arm back into the other arms/links hence the noise
went inside and changed my undies,showered and made another coffee :) contemplated how FUN this jeep is and how much money im saving doing this myself
,
Pulled Pitman arm No problems no need for another undie-changeover (I was contemplating some depends)
cleaned up original pitman arm slipped it on and tightened it up (one of dads old wrenches) I couldn't get enough oomph out of the wrench and didnt have a pipe large enough to go over the end, took a break and my brain started smoldering, the the light-bulb went on all bright
my wrench extension was there all the time provided by the old jeep herself one of her old dry-rotted Garters

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WARNING DO NOT DO THIS AT HOME DO NOT DO AS I DID
this shit is DANGEROUS
Ive never used these dam things nor had my father when I was around so my STUPIDITY is pegged very HIGH on the meter
vids i watched didnt help

I had these dam clamps clamped down in all sorts of configurations
without springs compressed by jacking the axle up
with jacking up the axle and releasing the jack
STILL zero room to get the spring over the lower pad like i needed another inch of space even with a pry bar
and i know the dam clamps were under some horrendous tension
and im sweating at this point swearing and praying its been 3 fricken hours, so im sitting and staring the dam spring down
and its laughing at me i know it is (and NO i dont need therapy but thinking my jeep needs an exorcism)
I took the brake caliper off and hung it off the tub
after and hour staredown i brought out "A" cure, i seen it on a utuber vid
My small bottle jack ive lugged around since i left home--short buss of 79 (another of Dads Gifts,and it still works :))
I also couldent get the Dam extended rubber bumper out,and the spring was jamming on the fricken rubber and cup so I took my saws-all to it and made MORE of a cluster-f#$k this girl is serious about her rubbers prying and swearing it finally jumped out
and here is where that EVIL short term memory sucks (in his description) he says if there no room, take the control arm bolt out
DAM im hoping the drivers side comes off easy-peasy because when i leave the desk tonite im ripping those arms out 1st thing :)

NOW the scary DONT DO THIS AT HOME
the friggen spring was STILL under extreme tension with the bolts backed out flush with the nuts
even in my stupid stage i knew better than to spin a nut off, id loose my nuts or brains splattered all over the garage
another thinkin session
the jeeps got tow bar hooks on the bumper :) spring sits nice among the welded eye hole tabs locking it methinks
so i put one end of the spring on my jack and the other end on the bumper tabs and jack the spring up
I now have kinda loose spring compressors and NOW ive got to lean down and LOOSEN the bolts off the nuts-- AM I NUTS OR WHAT
OUR FATHER WHOART IN HEAVEN
got them off and let the jack down
Ive done some scary shit in my days but this take the cake
im praying taking the control arms OFF will help me on the drivers side :)

More pics and posts coming soon :)
oh and i have new cups coming tomorrow :)
and the bolts were the short stock bolts not longer as i had read or thought
I couldent believe how much dirt and rocks i blew out of the top of the holes on top of the bumper assembly--wrong terminology ya i know
stick it under terminology-challenged :)

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well i had a buttload of info my sarcastic info typed out and the jeep vibes must be long reaching as i lost connection and hence lost all my humor
so now its back to the short buss version bacause ive fricken forgotten what all i had typed out FUBAR i tell ya
now right click-copying my tex as i go friggin computer :(
1- I want to THANK "FUSE" on here for his topic/Post Man he has helped me, immensely

I put my Big Boy undies "Depends" on (yes i had beans and hot dogs for dinner) now i crinkle when i walk snuck out to the garage without waking up the Dogs
and put on my extra large pants and shirt over my now medium shirt and pants (for some reason im loosing tons of weight and the docs are trying to figure out why) turn on my Pro-Pain turbo heater and sit and give the jeep the evil eye, cant hear you as the turbo is LOUD. reach for my notes, well crap, 12 pockets later
NO notes, so i sneaks back into the house, and get attacked by the two mutts thinkin there a break in,Barking there fool brains off at the FOOL that looks like the michalin man and crinkles when he walks along with the wife yelling "IS THAT YOU" yes its me, and i let the mutts out to bark at the Darkness and go down to find my notes,,yuppers right there on my desk DU
let the mutts in and back to the shop, open the door and get hit with a heat wave like Arizona in high summer by the time i get the turbo turned off im sweating
and my depends are damp Something tells me its going to be a stickie night

1st post
unhooked brake caliper and hung it up, unhooked shock removed it,
took off the lower control arm
beat the piss out of the bumper with and old long flat tipped screwdriver nuthin more nuthin, even with the overnight soak in pizzle-piss (blaster)
so break out MY "cure" my BBQ starter a huge honkin propane tank lighter :) and heat up the screwdriver tip, 4 times pushing it into the evil bumper once im about halfway into it just below the cup I use the spring to pry it out YAAAAAAAA winner goes to ME

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dropped the axle off the jack stand and easily pried the spring off with a pry-bar
(again THANK YOU FUSE)
cleaned old original dust coated springs, got my new shocks out, Bumpers along with the new sway-bar links.
the original springs slid right in TONS of room WOW
reinstalled all the Parts and used the tie down strap to back the axle up for the bolts
someofyou "MIGHT" at this point see the short buss version (EVIL JEEP) of my work :)
lets just say I laughed at myself and redid my foo-pa
and DAM I didnt get a pic of the compled work Brain-fart by this time i wuz TIRED but did HAVE FUN

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after some much needed sleep went back out and started on the passenger side was waiting for the mail delivery man with my bump cup and stop order
so I spent the time cleaning the Original steel rims 20yrs of dirt,dust and chicken poo (i had them stored into my back shed I had 18 food grade chickens in and somehow the got the plastic covering off them, they did taste good though) Bought some Rustolium wheel paint along with the spray cleaner at the autoparts store spent the day trying NOT to inhale FUMES Dear GOD that stuff is Nasty now that im a weezin old man (im my younger stupider days i never wore a respirator when i sprayed the furniture we built AKA STUPIDITY at its finest, hence part of why my LUNGS are SHOT
put the shock on but bolting only the upper end and tying it back out of the way also stuck the top of the sway-bar link in
all went good except for getting the control arm and the sway-bar link to line up for the bolts was
tools all ready parts showed up Onwards yaoldfool
getting the control arm to line up was a PAIN but i did get it lined up for the front bolt (i should have done the front bolt 1st-hindsight)
then finagling the jack up and down got the sway ling to line up caliper back on were good to go for the rims and drive out the driveway turn around
and start the belly and rear-end and we all know about those pesky NUTSERTS im so looking forwards to those NOT
Ill post a pic of the completed front on my next posting to start off the page

cheers all
John

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Forum recommendation: Paint those Rancho shocks before you put 'em on - they're noted for having crappy paint and rusting PDQ if you don't. I painted mine red because my Jeep is red.

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im going to spray everything with the fluid film so far everything I did spray before last winter Has Not rusted even the old shocks where they were sprayed
places where i missed does have rust. I need to do a better job this time

thats why when looking at my Pics it looks like my jeeps DIRTY, its all the road dust sticking to the fluid film :)
when i bought this jeep you could of eaten off the underneath of it except for the exhaust you can watch an exhaust system rust right out of the Box when it hits fresh air )
 
so i got my pics downloaded,took me awhile, Dam computer or my short-term brain farts
1st is the finished pic of the passenger front,no pic of the drivers, looks the same (I hope)
2cd put the original rims on it and lowered it onto the floor
and fought with the Pitman arm and ball joint (felt like I was in a catholic church-UP,Down,UP,Down)
from steering wheel to lookiee-lew under the bumper) Finally got it lined up and wiggled pried around to get into the hole
tightened the bolt up and stuffed the cotter pin in and bent it,
sat in my chair and looked at it
IT reminded me of High skool, everybody back then shackled there rear leaf springs and dropped there front coils with bolt on coil compressors
I had a 72 Javlin (AMC) so it was RELATED TO JEEP :) Dad would loan me his work bay and tools so i could fix it when i beat and broke it
(man i miss those PRE-Computer engine's) I would so love to dump a NON computer REAL distributor/Points six in this JEEP
and a lightbulb flashed on Bright
Ive Named my 05-LADY "TherAnBakAgan"
1-for the memory's of my Dad and his teachings
2-for all the close calls in life where GOD said NOT YET go back till I want you (and ive had quit a few)
3-I read the "Hobbit" when my BIG sister gave me the book when I was 9, and the series pretty much every year since then
4-Ive been fron Maine to every state except ("The Big Island"--NO BRIDGE ) and back to Maine
The Spellin---well i got a D+ in spellin and Math but they still gradumucated me :)
to all you spellin freaks out there YES i do use spell-check sometimes i like to be different and color outside the lines--that and that memory shit I deal with

Drove Her out of the garage, OMG my seat is no longer tilted back (please extinguish you cigarettes,Buckle up and put your seat in the upright position
YES ive got some massive TOE in and my wheel is off from center (that comes later) before i drive it to get NEW Shoes
checked garage floor then swept it (no missing parts on floor :) )
turned it around in driveway OMG what FUN
and im thunkin all i need is some wheeliee Bars a chute on the back tire rack and off to the drag races I go :) :) 0-60 in 69 seconds in death wobble mode
Got her Rear End Jacked up and dads huge jack stands under the frame with the little jacks under the axle at ride hight
removed the big heavy honkin wheels and BFG tires,
1ST THING REMOVED the DAM Control ARM see I DID learn and rememba somtin (THANK YOU AGAIN "FUSE")
then removed lower sway bar nut
then I removed the lower shock bolts and the upper shock bolts Brain-Fart upper shock bolts--I thunk they were 13mm and they spun out with my hammer drill and im going OH SHITTERS this is the nightmare I DONT WANT aka Gas tank removal then i tried a 12,, and POOF they back right out
all calm now and back to our original programming
then went to the stabilizer bar
Torks head bolt friggen pain in my ass,hands,thinking wrench choices, and searching for my DAM pipe i use for a leverage Bar
THEN for the fricken socket adapter for the wrench to tork socket, OK so i gets it all snapped free and spinnin now i have ZERO room (stupid GAS TANK AND
IDIOTS who designed this dam nightmare, I dont rememba my 90yj being so STUPID) Finally got it out when i figured out it was off the NUT and used a blunt tip punch to tap it the rest of the way out :)
then on to the bolt that hold this adapter onto the original seat —- there was NO getting this bolt free, pizzle pissed it, let it sit roto'd it till i vibrated the pins out of my old swivel, and had to beat them back down in, sat in my chair and wondered who "I" pissed off, and WHAT IDIOT didnt use anti-sieze back here
my thoughts--he probably like me was frustrated PUTTIN IN THIS NIGHTMARE and had HAD a few Jack Danial's too many and forgot
so out comes the NUT-SPLITTER well this didnt go all the well it SPLIT all right — IT split as in left quickly right before going through to the bolt and making a fricken mess
so out comes the trusty saws-all and 20 minutes of shaking and False-Teeth rattling slice and dice, then beat it with my punch and poof bolt pops out the back this thing is HEAVY steel with a zink? coating? with tons of rust inside and outside These folks should go into Condom Manufacturing--my second daughter was born from a thin-walled bump stop (TMI?) oh well :)
oh ya my new Bumper Cups and bolts showed up (the mail guy mustove heard me swearing and left the package at the shop door instead of coming in
SMART MAN :)
so there you have it so FAR. ILLLL BE BACK :)

cheers John

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OH forgot to mention
those are the original wheels and tires- p215x75x15
BUT I sprayed them with rustolium (trustoilium?) spray and pray paint just to see how BLACK heels looks
even spell check doesnt fix the spellin errors so im going with it
 
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Novak Conversions Jeep Wrangler TJ radiator