Our Baby Jeep - 03 Wrangler Rubicon

in4m8ionman

in4m8ionman

Member
Supporting Member
Joined
Jul 20, 2021
Messages
41
Location
Indianapolis, Indiana
IMG_0532.jpeg


Well, we bought a 2003 Jeep Wrangler Rubicon with around 198K miles. It is pretty clean with only one large spot of rust.

It is a 4.0L in-line 6 with automatic in Light Khaki Metallic (PJC) with a Khaki cloth interior. It has factory Fog Lights, and rock rails.

I said it is pretty clean, given that it is a 19 year old Jeep, but there are a bunch of things that need attention.
The AC does not work. One of the O2 sensors is out. The Fogs don't work. The wheels and tires are pretty much crap. There is the aforementioned rust spot (front left fender) and the handles, tow-hitch and rock rails are rusty. The plastics are weather-worn. The seats need scrubbed. The bumpers need work. There is a small dent in the right fender and the lens is busted.​

My plan is to clean it up and work to do a mild build, really, to restore it to what it was like when new, but with some additional goodies like larger wheels and tires.

I realize this is counter to most rock-crawler monster builds, but this Baby Jeep is going to just be a daily driver for me and my family.

Here is the build list with parts and instruction threads that I plan to use.

Upgrade to JK Wheels and Tires - COMPLETE
Facebook Marketplace Factory JK Wheel and Tires
Quadratec TJ to JK Wheel Adapters
1 of Quadratec 1.25" Wheel Adapter for 84-06 Jeep Wrangler YJ, TJ, & Cherokee XJ

Fix Fog light issue - COMPLETE
Turn Signal Switch for 2001-2006 Jeep Wrangler TJ w/ Fog Lights
https://wranglertjforum.com/threads...og-lights-fog-lights-that-wont-turn-off.3697/

HVAC Heater Control Knob - COMPLETE
HVAC Heater Control Knob (99-06 Jeep Wrangler TJ)

Replace Front Signal Lens - COMPLETE
Turn Signal/Parking Light; Amber (97-06 Jeep Wrangler TJ)

Replace (and Reverse) Rusted Door Handles - COMPLETE
OPR Door Handle; Black (97-06 Jeep Wrangler TJ w/ Full Doors)
https://wranglertjforum.com/threads/how-to-reverse-tj-door-handles.53652/

New Weathertech Front and Rear Floor Mats - COMPLETE
Weathertech DigitalFit Front and Rear Floor Liners; Black (97-06 Jeep Wrangler TJ)

Install Door Entry Guards - COMPLETE
Rugged Ridge All-Terrain Door Entry Guards (97-06 Jeep Wrangler TJ)

Replace Tail Lights - COMPLETE
Tail Light; Black Housing; Red/Clear Lens (98-06 Jeep Wrangler TJ)

Rust off Paint and Parts - COMPLETE
Rustoleum The Must for Rust
Rustoleum Rust Reformer.

Degrease and Detail the Engine - COMPLETE

Replace with Stock look Headlights - COMPLETE
https://www.extremeterrain.com/kchilites-h4-headlight-4230.html#customer_reviews

Refurbish Fog Lights - COMPLETE
https://wranglertjforum.com/threads/refurbishing-oem-fog-lights.7136/

Paint Black Parts - STARTED
Duplicolor Trim and Bumper Paint.
  • Fuel area - COMPLETE
  • Rear License Plate Mounting - COMPLETE
  • Rear Bumper and surrounding area - COMPLETE
  • Front Bumper and surrounding area - COMPLETE
  • Fenders
  • Side Mirrors
  • Frame Pieces - STARTED
Fix Blower Issue - COMPLETE
[URL]https://www.wranglerforum.com/...temp-control-wont-work.1805433/#post-26813081[/URL]
[URL]https://www.wranglerforum.com/...rost-and-floor-not-vents.374522/#post-5895802[/URL]

Fix Blend Door or Vacuum Leak - COMPLETE
[URL]https://wranglertjforum.com/threads/only-blows-out-the-defrost.12541/[/URL]
[URL]https://wranglertjforum.com/threads/air-wont-come-out-of-vents.2034/#post-103618[/URL]
[URL]https://www.jeepforum.com/forum/f9/tj-hvac-mode-selector-repair-3042753/[/URL]
[URL]https://wranglertjforum.com/th...ac-air-not-blowing-through-center-vents.2887/[/URL]
[URL]https://www.jeepforum.com/foru...er-ac-fan-blow-only-through-defroster-527339/[/URL]

Install USB in Dash -COMPLETE
https://wranglertjforum.com/threads/installing-a-3-0-dual-usb-plug-voltmeter.19055/
https://www.amazon.com/gp/product/B07L9Q5GD3/?tag=wranglerorg-20

Replace Radio with Factory-like Radio - COMPLETE
https://1factoryradio.com/chrysler-...2-10-radio-02-07-am-fm-cd-player-w-bluetooth/

Replace O2 sensors

Replace Exhaust
https://www.quadratec.com/products/17613_1231_07.htm

Paint Fenders (x2) - (PJC Color)
https://paintedautobodyparts.com/je...find=2004-jeep-wrangler-97-06-fenders-1086360

Replace or Repair Rocker Guards

Replace AC Compressor

New Seats

Here is how Baby Jeep looks right now. I will work to get better pictures.

IMG_0628.jpeg
 
Last edited:
  • Like
Reactions: JMT, taylormade73, Vasq and 1 other person
This site contains affiliate links for which Jeep Wrangler TJ Forum may be compensated.
Upgrade to JK Wheels and Tires

My first goal was to make sure that any driver would not slide off the road on bald tires. I also knew that adding JK wheels and tires was a pretty easy thing to do.

I researched this process on two great posts.
https://wranglertjforum.com/threads/how-to-run-jk-or-jl-wheels-on-a-tj.19285/http://www.smartenoughtodiy.com/jk-rims-on-tj-wrangler/
I found really clean stock 17" JK wheels on Facebook Marketplace that were very similar to the 16" originals.

I also bought these 1.25" Quadratec TJ to JK Wheel Adapters
1 of Quadratec 1.25" Wheel Adapter for 84-06 Jeep Wrangler YJ, TJ, & Cherokee XJ

Here are the original wheels
IMG_0360.jpeg


I had some fun getting the old lug nuts off
IMG_0570.jpeg


Ultimately, I had to replace a stud. Cut my hand in the process and needed a few stitches, but it was relatively easy.
IMG_0571.jpeg


Final Product
IMG_0627.jpeg
 
  • Like
Reactions: JMT
Fix Fog light issue

The Factory Fogs did not work for some reason. The PO told us that every time you turned them on, you couldn't turn them off and they drained the battery. Thanks to wranglertjforum.com I found this post.
https://wranglertjforum.com/threads...og-lights-fog-lights-that-wont-turn-off.3697/

I purchased a new signal switch from eBay.
Turn Signal Switch for 2001-2006 Jeep Wrangler TJ w/ Fog Lights

It was very easy to replace with no stitches or hiccups.

Once I replaced the switch and the fuse, it works great! Super Excited.

Now I need to disassemble the fogs and clean them up.
 
This site contains affiliate links for which Jeep Wrangler TJ Forum may be compensated.
Replace (and Reverse) Rusted Door Handles

The handles are super rusty and the rust is staining the paint.
IMG_0778.jpeg


I bought these handles
OPR Door Handle; Black (97-06 Jeep Wrangler TJ w/ Full Doors)

I also want to flip the handles because I don't like how they open when they are stock. They have always seemed counter-intuitive until I found out that they are like that because some TJ owners have had they doors ripped open by branches when they are on trails! Hilarious. Well, I know this is sacrilege, but I don't plan on being on too many tree-lined trails in the near future.
Here is an awesome thread on how to replace (and flip) the handles.
https://wranglertjforum.com/threads/how-to-reverse-tj-door-handles.53652/

MANY folks scared me that it would take a long time, but it was not too bad. I actually did it in my front entry while on work conference calls!
EEFAE555-D76D-4217-A7C8-B3FB6E96E038.jpeg


I was able to complete this project without much fanfare. The Post about it was invaluable. They look great now and are no longer backwards!
IMG_0794.jpeg


I still have to clean off the rust, but that is a project for another day.
 
Last edited:
  • Like
Reactions: JMT and Nickgsjeep
Here is a quick project trifecta...

HVAC Heater Control Knob
The original knob was missing. I bought this and it matches perfectly.
HVAC Heater Control Knob (99-06 Jeep Wrangler TJ)

Replace Front Signal Lens
The original lens was broken (right above the fender dent). I bought this and fixed it quickly.
Turn Signal/Parking Light; Amber (97-06 Jeep Wrangler TJ)

New Weathertech Front and Rear Floor Mats
I hated the mats that were in place when I bought it.
IMG_0791.jpeg


I bought these weathertechs and they fit perfectly.
Weathertech DigitalFit Front and Rear Floor Liners; Black (97-06 Jeep Wrangler TJ)
IMG_0793.jpeg
 
Replace Tail Lights

Ugh - don't you hate when a quick project turns south.
I bought these Tail Lights. They are pretty much what is on the Jeep now.
Tail Light; Black Housing; Red/Clear Lens (98-06 Jeep Wrangler TJ)

The problem was obvious when I took the lens off.
I knew there was rust somewhere because I saw the stains on the paint, but there was more than I expected.
IMG_0798.jpeg


I will probably slap this back on for now and do some research before I address it.
 
  • Like
Reactions: JMT, Nickgsjeep and thekidwithquestions
in4m8ionman said:
View attachment 273205

Well, we bought a 2003 Jeep Wrangler Rubicon with around 198K miles. It is pretty clean with only one large spot of rust.

It is a 4.0L in-line 6 with automatic in Light Khaki Metallic (PJC) with a Khaki cloth interior. It has factory Fog Lights, and rock rails.

I said it is pretty clean, given that it is a 19 year old Jeep, but there are a bunch of things that need attention.
The AC does not work. One of the O2 sensors is out. The Fogs don't work. The wheels and tires are pretty much crap. There is the aforementioned rust spot (front left fender) and the handles, tow-hitch and rock rails are rusty. The plastics are weather-worn. The seats need scrubbed. The bumpers need work. There is a small dent in the right fender and the lens is busted.​

My plan is to clean it up and work to do a mild build, really, to restore it to what it was like when new, but with some additional goodies like larger wheels and tires.

I realize this is counter to most rock-crawler monster builds, but this Baby Jeep is going to just be a daily driver for me and my family.

Here is the build list with parts and instruction threads that I plan to use.

Upgrade to JK Wheels and Tires - COMPLETE
Facebook Marketplace Factory JK Wheel and Tires
Quadratec TJ to JK Wheel Adapters
1 of Quadratec 1.25" Wheel Adapter for 84-06 Jeep Wrangler YJ, TJ, & Cherokee XJ

Fix Fog light issue - COMPLETE
Turn Signal Switch for 2001-2006 Jeep Wrangler TJ w/ Fog Lights
https://wranglertjforum.com/threads...og-lights-fog-lights-that-wont-turn-off.3697/

HVAC Heater Control Knob - COMPLETE
HVAC Heater Control Knob (99-06 Jeep Wrangler TJ)

Replace Front Signal Lens - COMPLETE
Turn Signal/Parking Light; Amber (97-06 Jeep Wrangler TJ)

Replace (and Reverse) Rusted Door Handles - COMPLETE
OPR Door Handle; Black (97-06 Jeep Wrangler TJ w/ Full Doors)
https://wranglertjforum.com/threads/how-to-reverse-tj-door-handles.53652/

New Weathertech Front and Rear Floor Mats - COMPLETE
Weathertech DigitalFit Front and Rear Floor Liners; Black (97-06 Jeep Wrangler TJ)

Install Door Entry Guards - COMPLETE
Rugged Ridge All-Terrain Door Entry Guards (97-06 Jeep Wrangler TJ)

Replace Tail Lights
Tail Light; Black Housing; Red/Clear Lens (98-06 Jeep Wrangler TJ)

Paint Black Parts - STARTED


Replace AC Compressor


Rust off Paint and Parts
The Must for Rust from Menards

Replace with Stock look Headlights
https://www.extremeterrain.com/kchilites-h4-headlight-4230.html#customer_reviews

Replace O2 sensor


Exhaust
https://www.quadratec.com/products/17613_1231_07.htm

Fenders (x2) - (PJC Color)
https://paintedautobodyparts.com/je...find=2004-jeep-wrangler-97-06-fenders-1086360

Replace Radio with Factory-like Radio
https://1factoryradio.com/chrysler-...2-10-radio-02-07-am-fm-cd-player-w-bluetooth/

Refurbish Fog Lights
https://wranglertjforum.com/threads/refurbishing-oem-fog-lights.7136/

Install USB in Dash
https://wranglertjforum.com/threads/installing-a-3-0-dual-usb-plug-voltmeter.19055/
https://www.amazon.com/gp/product/B07L9Q5GD3/?tag=wranglerorg-20

Here is how Baby Jeep looks right now. I will work to get better pictures.

View attachment 273296
Click to expand...
Is there a horse living in your garage?

in4m8ionman said:
BTW - We call the TJ "Baby Jeep" because I also own a 2021 Jeep Gladiator.

View attachment 273251
Click to expand...
Also a baby Jeep…. 😉
 
This site contains affiliate links for which Jeep Wrangler TJ Forum may be compensated.
Rust off Paint and Parts

BIG shoutout to Krud Kutter's The Must for Rust!

I got it in the mail (sold out everywhere around here) and sprayed it on the paint and viola!

I didn't even let it sit very long. I will come back later and finish this after today's chores are done.

IMG_0806.jpeg
 
  • Like
Reactions: Nickgsjeep and NashvilleTJ
Rust off Paint and Parts - Update 2

OK, spent the afternoon, working to remove the rust on Baby Jeep.

I also removed the rust and paint from behind the tail lights with an angle grinder and paint/rust removal pad.

IMG_0826.jpeg


The next step was to drill out and install some rivnuts in the old holes so that I have a strong connection between the tail light and body.
IMG_0831.jpeg


I also applied The Must For Rust onto the other exposed and rusted parts of the rear frame.

I am planning to paint the area behind the lights with rust encapsulator. I debating about painting it back to body color or not.

I will paint the rear frame area with black paint.

Here is a where I stopped for the day.

IMG_0833.jpeg
 
  • Like
Reactions: Nickgsjeep, NashvilleTJ and bobthetj03
Last night, before Men's Night at church, I got the rear masked and sprayed with Rustoleum Rust Reformer.

It went on nicely. I sprayed the frame that I could reach while I was at it.

I did order and receive some Light Khaki Metallic (PJC) and clear coat paint so I will probably spray behind the lights. I'm like that and can't not do it.

This morning, I sprayed the bumper and trailer bar and hitch with Duplicolor Trim and Bumper Paint.

IMG_0849.jpeg
 
  • Like
Reactions: JMT, Nickgsjeep, SoCalGlide and 1 other person
nice work tackling these little projects, your khaki color has always been one of my favorites...
 
  • Like
Reactions: Nickgsjeep
Top Bottom
Back