Judah the 1999 Wrangler Sport

Yasha

TJ Enthusiast
Original poster
Supporting Member
Joined
Nov 18, 2021
Messages
107
Location
Midwest, USA
Hello all, this is my new to me 1999 Jeep Wrangler Sport. It's been kept stock and includes factory hardtop. Manual with the AX-15. New to the forum so I apologize if this is posted in the wrong area and if I should be posting some of my queries in a tech and maintenance section somewhere.

It's a strange beast from what I've been reading because it lacks some features I thought were more standard. No center console, no tape and CD player, no rear defroster despite factory hard top. Wiring harness does not seem to include provision for rear defroster (but it does for rear windshield wiper) or potential overhead sound bar. All things which can be installed and this will be part of my projects for next year, after more important maintenance is completed. Luckily these are features which are pretty common to pop up used, so I'll probably add more than a couple missing premium factory options over time.

That said I am going around and replacing all the fluids. Already did engine, gearbox, and transfer case. I replaced the radiator (it was leaking) and hoses and I am in the process of flushing the engine coolant to remove stopleak from PO. Next up will be the axles and steering box. By the way, I attached a picture of the gearbox oil I found when draining. It was beige. Does this indicate anything particularly nasty I should prepare for? I caught a sample and have considered sending it for lab testing. But I'm not sure if it has ever been changed so it probably won't tell me anything useful.

Axles are 3.07, Dana 30 front and M35 in rear. Haven't replaced the fluid yet, it's on my list. Tires from PO are 28.9" (235/75R15). So according to this size chart I am geared way up for highway driving. This explains why the car feels so tired starting from stop and accelerating in 1st+2nd. Well, that and I am used to my daily driver which is a Camaro pushing a little over 500hp at the crank. Anyway I plan in the future to up the axles and for now I don't need to move anything particularly heavy, at most 100-200 pounds in the trunk. Besides, the extra 0.6" over stock floor clearance is a benefit for my working needs. So I'm just going to casually be on the prowl for good used beefier axles on sale locally and one day think about building 4.10 or 4.56s. Would like to lift the car a few more inches in the future.

Stay tuned.

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First...Its not a "car" and it doesn't have a trunk. Its a Jeep. It has a cargo area or bed.

Second..that fluid in the jar you have is pretty typical of having water mixed into the oil. Good thing you changed it.
 
Yeah yeah no doubt someone would take issue if I said safari truck instead, there's no winning. Just ask the BMV, where at some point before I owned it my new vehicle was titled as a "cherokee SUV" make + model. Not kidding.

Very glad I did. I'm probably going to change it again in a few months to give the box a better cleanout. Maybe 6 months at most, at least I don't think I should wait the usual interval.

Changed rear differential fluid a few days ago, it actually looked pretty clean. Had to pull the cover to drain, and saw the gears look to be in good condition with no signs of abuse or severe wear. Pinion seal looks to be leaking so I'll end up changing that and probably the bearings for good measure when I re-gear. Next up steering box.
 
4.10 axles have been located. Super excited for this upgrade. Plan to media blast, paint, and replace seals then swap in. Today was day 1 at the junkyard, got lucky and found two donors there. I say day 1 because the Jeep I was working under, well the mounting hardware holding the axles via the trailing arms etc are too badly rusted to get off and the yard doesn't allow cutting (could easily get them off with the axles out on the bench in my shop). Anyway I thought maybe I'll try to get just the gears + carrier, it looks like I need either 7mm or 9/32" wrench to pull the screw holding the retaining pin in the stock open diff carrier? Can someone confirm? I read I needed 8mm, well that definitely isn't right and unfortunately I didn't have 7mm or 9/32" with me. So, day 2.

I'm also tempted to snag some alloy 15" wheels from a cherokee if I can find some. I hate steelies. Want to go up to 31" tires anyway.

Day 2, tomorrow, will involve first driving to another yard where I got a lead on another potential donor to see if the axles are in any better shape before I continue. I'd say it's time to learn how to shim a differential carrier but, I think the yard price for the whole axle is less than pulling the gears and carrier only. Anyway, fingers crossed tomorrow brings better luck.